Method for manufacturing color-changing photovoltaic module and color-changing photovoltaic module

Abstract

The invention provides a method for manufacturing a color-changed photovoltaic module and the color-changed photovoltaic module. The method comprises the steps that texturing, diffusion and film coating are carried out on a silicon wafer to form a photovoltaic structure, and the reflectivity range of the film coating side of the photovoltaic structure is 3%-10%; forming a battery piece through the photovoltaic structure; the front glass is coated with an antireflection film with the thickness ranging from 50 nm to 220 nm; and sequentially laminating the antireflection film, the front glass, the front adhesive film and the battery piece by using the front adhesive film of which the light transmittance is greater than or equal to 80%. The antireflection film is coated on the front glass and the light transmittance of the front adhesive film is controlled, so that the light transmittance of the whole photovoltaic module is increased, and more light enters the battery piece; the difference of solar light reflection wavebands is realized by controlling the thickness of the antireflection film; the coating of the antireflection film, the control of the transmissivity of the front adhesive film and the improvement and limitation of the reflectivity of the photovoltaic structure act together to change the color of the photovoltaic module and realize the compensation of the power generation efficiency of the photovoltaic module at the same time.

Description

Technical Field

[0001] This disclosure relates to the field of photovoltaic technology, and in particular to a method for manufacturing color-changing photovoltaic modules and color-changing photovoltaic modules. Background Technology

[0002] With the continuous development and progress of the photovoltaic industry, the market has placed higher performance demands on photovoltaic products. Since photovoltaic modules need to absorb the most intense wavelengths of natural light to achieve good power generation, the ideal situation is complete absorption of natural light with no reflection. This would result in photovoltaic modules displaying a single, dark color. Therefore, the mainstream colors of solar cells in current technology are relatively limited, generally black or blue.

[0003] Generally, changing the color of photovoltaic modules involves printing a colored layer onto the glass, but this often results in a loss of power generation efficiency. There is a contradiction between changing the color of photovoltaic modules and improving their power generation efficiency. Summary of the Invention

[0004] In view of this, it is necessary to provide a method for manufacturing color-changing photovoltaic modules to address the above problems and resolve the issue between color changing and power generation efficiency of photovoltaic modules.

[0005] This disclosure provides a method for manufacturing a color-changing photovoltaic module, including texturing, diffusion, and coating a silicon wafer to form a photovoltaic structure, wherein the reflectivity of the coated side of the photovoltaic structure ranges from 3% to 10%; forming a solar cell through the photovoltaic structure; coating an anti-reflection film with a thickness ranging from 50 nm to 220 nm on the front glass; and using a front encapsulant film with a light transmittance greater than or equal to 80%, sequentially stacking the anti-reflection film, the front glass, the front encapsulant film, and the solar cell.

[0006] The method for manufacturing color-changing photovoltaic modules disclosed herein increases the overall light transmittance of the photovoltaic module by coating an anti-reflection film on the front glass and controlling the light transmittance of the front encapsulant film, allowing more light to enter the solar cells. Differences in the reflected wavelengths of solar light are achieved by controlling the thickness of the anti-reflection film. The reflectivity of the photovoltaic structure is increased and limited, allowing more colors of other wavelengths of solar light to be reflected without significantly reducing the power generation efficiency of the solar cells. The combined effect of the anti-reflection film coating, the control of the front encapsulant film's transmittance, and the increase and limitation of the photovoltaic structure's reflectivity alters the color of the photovoltaic module while compensating for the reduced power generation efficiency of the solar cells.

[0007] In some embodiments, the coating step includes: depositing an antireflective coating, wherein the product of the refractive index of the antireflective coating and the thickness of the antireflective coating is in the range of 80 nm to 160 nm, or 260 nm to 440 nm.

[0008] This method allows the photovoltaic structure to exhibit different colors by controlling the deposition range of the refractive index and thickness of the antireflective film, while ensuring the range of reflectivity on the coated side of the photovoltaic structure.

[0009] In some embodiments, the method for manufacturing color-changing photovoltaic modules further includes: forming front glass, the step of forming front glass including: forming ultra-clear glass through a float glass process or a patterned glass process; and acid etching the ultra-clear glass.

[0010] The front glass formed in this method is ultra-clear glass, which has high light transmittance to allow more light to enter the solar cell. Furthermore, the embossing and acid etching processes increase the randomness of reflections on the front glass, improving the uniformity of the color display.

[0011] In some embodiments, the step of forming the front adhesive film includes: forming a colorless front adhesive film; or forming the front adhesive film based on a second raw material including pigments.

[0012] In this method, the colorless front film ensures high light transmittance. The method involves adding color masterbatch to the second raw material to change the color of the front film while maintaining a certain level of light transmittance.

[0013] In some embodiments, the method for manufacturing color-changing photovoltaic modules further includes: forming a backsheet made of transparent glass or an opaque sheet; forming a back film made of transparent or opaque material; forming a laminate based on the stacked antireflective film, front glass, front film, solar cells, back film, and backsheet; forming a first color layer on the surface of the frame; framing the laminate on the frame; and forming a second color layer on the surface of the junction box, mounting the junction box to the backsheet, and electrically connecting the junction box to the solar cells.

[0014] In this method, the overall color of the photovoltaic module formed through the above steps is changed and the overall color is unified.

[0015] In some embodiments, a method for manufacturing a color-changing photovoltaic module includes: coating an antireflective film with a thickness of 90 nm; forming a front encapsulant film with a first color and a light transmittance of 87%; forming an antireflective film with a refractive index product of 90 nm and a film thickness of 90 nm; forming a photovoltaic structure with a reflectance of 6% on the coated side; forming a back encapsulant film of a transparent material with a light transmittance of 91%; forming a back sheet of transparent glass material; and forming a first color layer with the first color on the surface of the frame.

[0016] The method can form a photovoltaic module of the first color through the above steps without significantly reducing the power generation efficiency of the photovoltaic module of the first color.

[0017] In some embodiments, a method for manufacturing a color-changing photovoltaic module includes: coating an antireflective film with a thickness of 90 nm; forming a front encapsulant film of a transparent material with a light transmittance of 91%; forming an antireflective film with a refractive index product of 90 nm and a film thickness of 90 nm; forming a photovoltaic structure with a reflectance of 6% on the coated side; forming a back encapsulant film of a second color with a light transmittance of 60%; forming a backsheet of transparent glass material; forming a first color layer of the second color on the surface of the frame; and forming a second color layer of the second color on the surface of the junction box.

[0018] This method can form a photovoltaic module with both sides being the second color through the above steps without significantly reducing the power generation efficiency of the second-color photovoltaic module.

[0019] In some embodiments, a method for manufacturing a color-changing photovoltaic module includes: coating an antireflective film with a thickness of 100 nm, such that the transmittance of the front glass and the antireflective film is 88%; forming a front encapsulant film with a third color and a transmittance of 87%; forming an antireflective film with a refractive index and film thickness product of 330 nm; forming a photovoltaic structure with a reflectance of 6% on the coated side; forming a back encapsulant film of a transparent material with a transmittance of 91%; forming a back sheet of transparent glass material; forming a first color layer with a third color on the surface of the frame; and forming a second color layer with a third color on the surface of the junction box.

[0020] The method can form a third-color photovoltaic module through the above steps without significantly reducing the power generation efficiency of the third-color photovoltaic module.

[0021] In some embodiments, the steps of forming the solar cell include: printing electrodes and sintering the photovoltaic structure.

[0022] The process of forming solar cells through photovoltaic structures in this method is easy to operate and has low cost.

[0023] This disclosure provides a color-changing photovoltaic module, manufactured according to the steps of the method for manufacturing a color-changing photovoltaic module described above.

[0024] The color-changing photovoltaic module provided in this embodiment changes the color while compensating for power generation efficiency. Attached Figure Description

[0025] Figure 1 This is a flowchart illustrating a method for manufacturing color-changing photovoltaic modules provided in an embodiment of this disclosure;

[0026] Figure 2 This is a general flowchart of a method for manufacturing color-changing photovoltaic modules provided in the embodiments of this disclosure;

[0027] Figure 3This is a schematic diagram comparing the transmitted light wavelengths of the transparent glass, the terracotta-colored film with 88% light transmittance, and the laminated terracotta-colored film with 88% light transmittance and glass provided in the embodiments of this disclosure.

[0028] Figure 4 This is a schematic diagram comparing the transmitted light wavelengths of the transparent glass, the terracotta-colored film with 85% light transmittance, and the laminated terracotta-colored film with 85% light transmittance and glass provided in the embodiments of this disclosure.

[0029] Figure 5 This is a schematic diagram of the structure of the color-changing photovoltaic module provided in the embodiments of this disclosure.

[0030] Reference numerals: 1000, Method for manufacturing color-changing photovoltaic modules; 100, Color-changing photovoltaic module; 10, Laminate; 1, Photovoltaic structure; 11, Silicon wafer; 111, Anti-reflective film; 2, Front glass; 3, Anti-reflective film; 4, Front encapsulant film; 5, Backsheet; 6, Back encapsulant film; 7, Frame; 8, First color layer; 9, Junction box; 12, Second color layer. Detailed Implementation

[0031] The technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments of this disclosure, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this disclosure.

[0032] It should be noted that when a component is said to be "installed on" another component, it can be directly on the other component or it may be in a component that is centered on it. When a component is said to be "set on" another component, it can be directly set on the other component or it may also be in a component that is centered on it. When a component is said to be "fixed to" another component, it can be directly fixed to the other component or it may also be in a component that is centered on it.

[0033] The structural dimensions shown in the accompanying drawings in this article do not represent actual dimensions and may be adjusted as needed during actual production. The directional terms "up," "down," "left," and "right" used in this article refer to the orientation shown in the drawings and should not be considered as limitations on the actual use of the product unless explicitly stated otherwise.

[0034] The terms "first," "second," "third," etc., used in this article are only used to distinguish the same features. Understandably, the "first" in this article can also be called the "second," and the "second" can also be called the "first."

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure. The term "or / and" as used herein includes any and all combinations of one or more of the associated listed items.

[0036] like Figure 1 As shown, Figure 1 A flowchart of a method 1000 for manufacturing a color-changing photovoltaic module according to an embodiment of this disclosure is shown. The method 1000 for manufacturing a color-changing photovoltaic module provided in this embodiment of the disclosure includes the following steps S101 to S104.

[0037] Combination Figure 5 As shown, in step S101, the silicon wafer 11 is texturized, diffused, and coated to form a photovoltaic structure 1, wherein the reflectivity of the coated side of the photovoltaic structure 1 ranges from 3% to 10%. Exemplarily, the silicon wafer 11 is texturized and diffused on one side only. Exemplarily, the reflectivity of the coated side of the photovoltaic structure 1 can be 4%, 6%, or 8%.

[0038] In step S102, a solar cell is formed using the photovoltaic structure 1. Exemplarily, a solar cell (not shown) is formed after adding positive and negative electrodes (not shown) to the coating side of the photovoltaic structure 1.

[0039] Step S103: Apply an antireflective coating 3 with a thickness ranging from 50 nm to 220 nm to the front glass 2. Exemplarily, the first surface of the front glass 2 is coated with the antireflective coating 3.

[0040] In step S104, using a front-side encapsulating film 4 with a light transmittance greater than or equal to 80%, the anti-reflective film 3, the front glass 2, the front-side encapsulating film 4, and the solar cell are sequentially stacked. Exemplarily, the front-side encapsulating film 4 is stacked on the second side of the front glass 2, from top to bottom, with the anti-reflective film 3, the front glass 2, the front-side encapsulating film 4 located on the coated side of the photovoltaic structure 1. Exemplarily, the front-side encapsulating film 4 is used to connect the solar cell and the front glass 2.

[0041] The present disclosure provides a method 1000 for manufacturing color-changing photovoltaic modules. This method utilizes the combined effects of coating an anti-reflection film 3 of a specific thickness on the front glass 2, controlling the light transmittance of the front adhesive film 4, and increasing and limiting the reflectance of the photovoltaic structure 1, so as to achieve color-changing of the photovoltaic module without significantly reducing the power generation efficiency of the photovoltaic module.

[0042] This method 1000 increases the overall light transmittance of the photovoltaic module by coating an anti-reflection film 3 on the front glass 2 and controlling the light transmittance of the front encapsulant film 4, allowing more light to enter the solar cells. By controlling the thickness of the anti-reflection film 3, the difference in the reflected wavelength of solar light is achieved. The increased reflectivity of the photovoltaic structure 1 allows more colors of other wavelengths of solar light to be reflected, without significantly reducing the power generation efficiency of the solar cells. The coating of the anti-reflection film 3, the control of the transmittance of the front encapsulant film 4, and the combined effect of the increased and limited reflectivity of the photovoltaic structure 1 change the color of the photovoltaic module and compensate for the power generation efficiency of the photovoltaic module.

[0043] In the method 1000 for manufacturing color-changing photovoltaic modules provided in this disclosure, steps S101 and S102 can be performed first, followed by steps S103 and S104. In other embodiments, steps S101 and S102 can be performed after step S103, and step S104 can be performed last. It is understood that steps S101 and S103 can be performed simultaneously.

[0044] In other embodiments, the method may further include: forming a photovoltaic structure 1 with a reflectivity ranging from 3% to 10% on the coated side, forming a solar cell using the photovoltaic structure 1, forming a front encapsulant film 4 with a transmittance ranging from 80% to 93%, and stacking the front encapsulant film 4 onto one side of the coated side of the solar cell, then coating an antireflective film 3 with a thickness ranging from 50 nm to 220 nm on the front glass 2, and stacking the side of the front glass 2 away from the antireflective film 3 onto the front encapsulant film 4.

[0045] The silicon wafer 11 is texturized, diffused, and coated to form the photovoltaic structure 1. The reflectivity of the coated side of the photovoltaic structure 1 can be measured using an ellipsometer, which provides a relatively accurate reflectivity measurement. The solar cell is formed after electrode printing and sintering processes on the coated side of the photovoltaic structure 1. Since the electrodes are made of silver or aluminum, which have high reflectivity, and the irregular shape of the printed electrodes and the varying electrode areas for different solar cells, the reflectivity of the solar cell is affected by these factors and cannot be accurately measured.

[0046] When the reflectivity of the coated side of photovoltaic structure 1 increases to 3% or higher, the color of the photovoltaic module can be changed. Simultaneously, as the reflectivity of the coated side increases, the power generation efficiency of the photovoltaic module gradually decreases. When the reflectivity of the coated side of photovoltaic structure 1 increases to greater than 10%, the power generation efficiency of the photovoltaic module decreases significantly, and the substantial loss in power generation efficiency is difficult to compensate for. Therefore, when the reflectivity of the coated side of photovoltaic structure 1 is in the range of 3% to 10%, the color of the photovoltaic module can be changed without significantly reducing its power generation efficiency.

[0047] For example, the thickness of the antireflective coating 3 can be 60nm, 90nm, 100nm, or 170nm. The thickness of the antireflective coating 3 significantly affects the color of sunlight reflection, resulting in different colors of reflective effect from antireflective coatings 3 of different thicknesses. When the thickness of the antireflective coating 3 is less than 50nm, the color change of the photovoltaic module is small. When the thickness of the antireflective coating 3 is greater than 220nm, the coating process is time-consuming and costly, making it difficult to implement. Therefore, when the thickness of the antireflective coating 3 is in the range of 50nm to 220nm, the coating cost is low, the difference in the reflected wavelength of solar light can be controlled, and the overall transmittance of the photovoltaic module is increased, allowing more light to enter the solar cells, while simultaneously achieving color modification of the photovoltaic module.

[0048] For example, the light transmittance of the front adhesive film 4 can be 87%, 90%, or 91%. For example, the light transmittance of the front adhesive film 4 can reach 93%. The higher the light transmittance of the front adhesive film 4, the better the light transmission effect.

[0049] By controlling the proportions, temperature, and time of various chemical materials (acids / alkalis, etc.) added during the texturing process, and by combining this with the comprehensive effect of coating, the reflectivity range required for photovoltaic structure 1 can be achieved.

[0050] In some embodiments, the step of coating the silicon wafer includes: depositing an antireflective film 111, wherein the product of the refractive index of the antireflective film 111 and the thickness of the antireflective film 111 is in the range of 80 nm to 160 nm, or 260 nm to 440 nm.

[0051] In this method, by controlling the deposition range of the refractive index and film thickness of the antireflective film 111, the photovoltaic structure 1 can exhibit different colors while ensuring the range of reflectivity on the coated side.

[0052] refer to Figure 5 After texturing, the surface of silicon wafer 11 is irregular. Since the thickness of antireflective film 111 is a fixed value, the surface shape of antireflective film 111 after deposition is consistent with the surface shape of silicon wafer 11.

[0053] For example, an antireflective coating 111 with a refractive index product ranging from 80 nm to 160 nm is deposited on a texturized and diffused silicon wafer. The antireflective coating 111 exhibits a terracotta color after reflecting sunlight. For example, the thickness of the antireflective coating 111 is 45 nm, and the refractive index of the antireflective coating 111 can be 2.

[0054] For example, an antireflective coating 111 with a refractive index product ranging from 260 nm to 440 nm is deposited on a texturized and diffused silicon wafer. This antireflective coating 111 appears yellow after reflecting sunlight. For example, the thickness of the antireflective coating 111 is 165 nm, and the refractive index of the antireflective coating 111 can be 2.

[0055] In some embodiments, the method 1000 for manufacturing color-changing photovoltaic modules further includes: forming a front glass 2. The step of forming the front glass 2 includes: forming ultra-clear glass through a float glass process or a patterning process; and acid etching the ultra-clear glass.

[0056] The front glass 2 formed in this method is ultra-clear glass, which has high light transmittance, allowing more light to enter the solar cell. Furthermore, the embossing and acid etching processes increase the randomness of reflection in the front glass 2, improving the uniformity of the color display.

[0057] For example, the light transmittance of ultra-clear glass is greater than 91.5%. It is understood that ultra-clear glass can also be formed using a patterned manufacturing process.

[0058] In other embodiments, ordinary glass may also be used as the front glass 2.

[0059] In some embodiments, the refractive index of the antireflective coating 3 ranges from 1.2 to 1.6. This setting ensures the light transmittance of the antireflective coating 3.

[0060] For example, adding a small amount of color masterbatch to the antireflective film 3 can have an auxiliary effect on the color of the antireflective film 3.

[0061] For example, the color masterbatch is terracotta-colored or yellow. It is understood that the color of the color masterbatch is selected as a preset color, which corresponds to the color required for the color-modified photovoltaic module 100 to be formed.

[0062] For example, the refractive index of the antireflective coating 3 can be 1.2, 1.5 or 1.6.

[0063] For example, the first raw material of the antireflective membrane 3 may be silicon oxide, magnesium fluoride or other materials.

[0064] In some embodiments, the step of forming the front adhesive film 4 includes: forming a colorless front adhesive film 4; or forming the front adhesive film 4 based on a second raw material including pigments.

[0065] In this method, the light transmittance of the front adhesive film 4 can be ensured by using a transparent material. The method involves adding pigment to the second raw material to change the color of the front adhesive film 4, while the translucent material ensures the light transmittance.

[0066] For example, the second raw material of the front adhesive film 4 includes ethylene-vinyl acetate copolymer (EVA) or polyolefin elastomer (POE), etc.

[0067] For example, the pigment can be an organic pigment or an inorganic pigment. It is understood that the color of the pigment is selected as a preset color, which corresponds to the color required for the color-modified photovoltaic module 100 to be formed.

[0068] refer to Figure 2 In some embodiments, the method 1000 for manufacturing color-changing photovoltaic modules further includes steps S105 to S109:

[0069] Step S105: Form a back plate 5 made of transparent glass or opaque sheet material. It is assumed that the light transmittance of the opaque material is 0, and the light transmittance of the transparent material is greater than 0.

[0070] Step S106: Form a backing film 6 of transparent or opaque material.

[0071] Step S107: Based on the stacked antireflective film 3, front glass 2, front adhesive film 4, battery cell, back adhesive film 6 and back sheet 5, a laminate 10 is formed.

[0072] Step S108: Form a first colored layer 8 on the surface of the frame 7; frame the laminate 10 on the frame 7.

[0073] Step S109: Form a second colored layer 12 on the surface of the junction box 9, install the junction box 9 on the back plate 5 and electrically connect the junction box 9 to the battery cell.

[0074] In this method, the overall color of the color-changing photovoltaic module 100 formed through the above steps is changed compared to the base color of black or blue, and the overall color is unified.

[0075] In the method 1000 for manufacturing color-changing photovoltaic modules provided in this disclosure, step S105 can be performed first, followed by step S106. In other embodiments, step S105 can be performed after step S106. It is understood that steps S105 and S106 can be performed simultaneously.

[0076] For example, the material of the back adhesive film 6 is the same as the material of the front adhesive film 4.

[0077] For example, the backplate 5 is made of transparent glass, and the back film 6 is made of transparent material. The colors of the colored layer of the frame 7 and the colored layer of the junction box 9 are selected to be the colors required for the color-changing photovoltaic module 100 to be formed, for example, the colors of the solar cells.

[0078] For example, the back film 6 is an opaque material and its color corresponds to the color required for the color-changing photovoltaic module 100 to be formed, and the back sheet 5 is an opaque board material corresponding to the color of the photovoltaic module. The light transmittance of the back sheet 5 and the back film 6 combined can be less than 70%.

[0079] For example, the color of the first color layer 8 is the same as the color of the second color layer 12.

[0080] In some embodiments, the steps of forming the solar cell include: performing a printing electrode process and a sintering process on the photovoltaic structure 1.

[0081] The process of forming solar cells through photovoltaic structure 1 in this method is easy to operate and has low cost.

[0082] For example, the electrode material is silver, and the shape of the printed electrode is not limited.

[0083] Table 1 shows the actual light transmittance of glass, transparent film, and various colored films.

[0084] Table 1

[0085] Single material Actual transmittance % 3.2mm glass 92.01％ 406PS film 92.36％ Terracotta-colored film with 88% light transmittance 88.16％ terracotta-colored film with 85% light transmittance 84.48％ terracotta-colored film with 80% light transmittance 81.25％ terracotta-colored film with 75% light transmittance 74.61％ terracotta-colored film with 71% light transmittance 69.01％ terracotta-colored film with 55% light transmittance 63.34％

[0086] Table 2 shows the actual light transmittance of glass, transparent film, or various colored films laminated together, as well as the differences in actual light transmittance between them.

[0087] Table 2

[0088]

[0089] Test data shows that the closer the light transmittance of the film is to that of glass, the smaller the change in light transmittance after combining with glass. For example, the light transmittance of an 85% light-transmitting film + glass is only 1.34% less than that of the film alone.

[0090] refer to Figure 3 The horizontal axis represents the wavelength of visible light, and the vertical axis represents the transmittance. From a spectral perspective, the combination of the terracotta-colored film with a transmittance of 88% and 3.2mm glass has a transmittance in the visible light wavelength range of less than 520nm that exceeds that of the terracotta-colored film monomer in the visible light wavelength range of less than 520nm.

[0091] refer to Figure 4 Within the visible light wavelength range, the transmittance of the terracotta-colored film at 85% is consistently greater than that of the combination of the terracotta-colored film at 85% and 3.2mm glass.

[0092] In some comparative examples, the reflectivity of the coated side of the photovoltaic structure 1 with an N-type gridless solar cell is approximately 1.1%. In the embodiments of this disclosure, compared to the comparative examples, when the reflectivity of the coated side increases to 4%-5%, the color of the color-changing photovoltaic module 100 can change, at which point the incident light loss is approximately 3%-4%. Therefore, coating the front glass 2 with an anti-reflection film 3 can improve the light transmittance of the photovoltaic module and compensate for the incident light loss due to the increased reflectivity of the coated side of the solar cell.

[0093] In some comparative examples, a photovoltaic structure 1 using colored glass with a light transmittance of 75%, a transparent film with a light transmittance of 92% on both the front and back, and a reflectance of 2% often has a combined light transmittance of less than 70%, and the coated side of the photovoltaic structure 1 often has a relatively dark color due to its low reflectance.

[0094] This embodiment uses a front glass 2 with 90% light transmittance, a colored film with 87% light transmittance, and a photovoltaic structure 1 with 4% reflectance. The combined light transmittance is greater than or equal to 86%, which can reflect more of the color of the solar cells 1, thereby changing the color of the photovoltaic module and making the overall color appearance of the photovoltaic module brighter.

[0095] Example 1: A method 1000 for manufacturing a color-changing photovoltaic module includes: coating an antireflective film 3 with a thickness of 90 nm; forming a front encapsulant film 4 with a light transmittance of 87% and a first color; forming an antireflective film 111 with a refractive index product of 90 nm and a film thickness of 45 mm, wherein the antireflective film 111 has a refractive index of 2; forming a photovoltaic structure 1 with a reflectance of 6% on the coated side; forming a back encapsulant film 6 made of transparent material with a light transmittance of 91%; forming a back sheet 5 made of transparent glass material; and forming a first color layer 8 with a first color on the surface of a frame 7.

[0096] The method can form a photovoltaic module of the first color through the above steps without significantly reducing the power generation efficiency of the photovoltaic module of the first color.

[0097] For example, the first color is terracotta, one of the most common colors for residential roofs. Photovoltaic modules are often directly mounted on the roof surface, and the back of the photovoltaic modules is not visible in applications. Therefore, for such applications, only the front color needs to be considered. The steps to form a terracotta-colored photovoltaic module on the front are as follows: a single-layer antireflective film 3 with a thickness of 90nm is coated on the upper surface of the front glass 2. The first raw material is silicon oxide, and the antireflective film 3 exhibits a yellowish-red reflected light. Iron oxide is used to color the front adhesive film 4 to form a terracotta-colored POE film with a light transmittance of 87%, forming a photovoltaic structure 1 with a reflectance of 6% on the coated side. The antireflective film 111 has a thickness of 45mm and a refractive index of 2. Therefore, the refractive index of the antireflective film 111 is related to the film thickness. The product is 90nm. A solar cell is formed through photovoltaic structure 1; a transparent POE back film 6 with a light transmittance of 91% is formed; a transparent glass backsheet 5 is formed; then, based on the sequentially stacked antireflective film 3, front glass 2, front film 4, solar cell, back film 6, and backsheet 5, a laminate 10 is formed, at which point the front of the laminate 10 is terracotta-colored; a first terracotta-colored color layer 8 is sprayed onto the outer surface of the frame 7, and the laminate 10 is fixed to the frame 7 by a frame mounting process. This forms the entire photovoltaic module with a terracotta-colored front.

[0098] Example 2, a method 1000 for manufacturing a color-changing photovoltaic module includes: coating an antireflective film 3 with a thickness of 90 nm; forming a front encapsulant film 4 of a transparent material with a light transmittance of 91%; forming an antireflective film 111 with a refractive index product of 90 nm and a film thickness of 45 mm, wherein the antireflective film 111 has a refractive index of 2; forming a photovoltaic structure 1 with a reflectance of 6% on the coated side; forming a back encapsulant film 6 of a second color with a light transmittance of 60%; forming a backplate 5 of transparent glass material; forming a first color layer 8 of the second color on the surface of a frame 7; and forming a second color layer 12 of the second color on the surface of a junction box 9.

[0099] This method can form a photovoltaic module with both sides being the second color through the above steps without significantly reducing the power generation efficiency of the second-color photovoltaic module.

[0100] For example, the second color is terracotta. To achieve higher power generation efficiency of the photovoltaic module while maintaining the second color, the light transmittance of the front side of the photovoltaic module needs to be increased, thus forming a double-sided terracotta-colored photovoltaic module. The steps for forming a double-sided terracotta-colored photovoltaic module are as follows: a single-layer antireflective film 3 with a thickness of 90nm is coated on the upper surface of the front glass 2. The first raw material is silicon oxide, and the antireflective film 3 exhibits a yellowish-red reflected light; a transparent front film 4 with a light transmittance of 91% is formed, and a photovoltaic structure 1 with a reflectance of 6% on the coated side is formed. The antireflective film 111 has a thickness of 45mm and a refractive index of 2. Therefore, the product of the refractive index and the thickness of the antireflective film 111 is 90nm. A solar cell is formed through the photovoltaic structure 1; iron oxide is used to color the back film 6 to form a transparent film. A 60% light-reflecting POE film in a terracotta color is used to form a backsheet 5, which is then used to form a transparent glass backsheet. A laminate 10 is then formed by sequentially layering an anti-reflective film 3, a front glass 2, a front POE film 4, solar cells, a back POE film 6, and the backsheet 5. At this point, both the front and back sides of the laminate 10 are terracotta-colored. A first terracotta-colored layer 8 is sprayed onto the outer surface of the frame 7, and the laminate 10 is then fixed in place by a frame installation process. A second terracotta-colored layer 12 is sprayed onto the outer surface of the junction box 9, and the junction box 9 is installed on the backsheet 5 and electrically connected to the solar cells. This completes the photovoltaic module assembly, which is terracotta-colored on both sides.

[0101] Understandably, since the color of the back of a photovoltaic module does not affect the absorption of light by the front of the module, the color of the back has little impact on the power generation efficiency of the photovoltaic module. The back film 6 is terracotta-colored while the front film 4 is transparent, which increases the light transmittance of the front. The back is terracotta-colored and the front is also terracotta-colored.

[0102] The cost of producing double-sided terracotta-colored photovoltaic modules is relatively low, making them suitable for scenarios such as carports where the back color is critical. They can cover the color difference on the back of the solar cells and have little impact on the power generation of the photovoltaic modules.

[0103] Example 3, a method 1000 for manufacturing a color-changing photovoltaic module includes: coating an antireflective film 3 with a thickness of 100 nm, such that the transmittance of the front glass 2 and the antireflective film 3 is 88%; forming a front encapsulant film 4 with a transmittance of 87% and a third color; forming an antireflective film 111 with a refractive index and film thickness product of 330 nm, wherein the thickness of the antireflective film 111 is 165 mm and the refractive index of the antireflective film 111 is 2; forming a photovoltaic structure 1 with a reflectance of 6% on the coated side; forming a back encapsulant film 6 of transparent material with a transmittance of 91%; forming a back sheet 5 of transparent glass material; forming a first color layer 8 of the third color on the surface of the frame 7; and forming a second color layer 12 of the third color on the surface of the junction box 9.

[0104] The method can form a third-color photovoltaic module through the above steps without significantly reducing the power generation efficiency of the third-color photovoltaic module.

[0105] For example, the third color is yellow. The steps to form a yellow photovoltaic module on the front side are as follows: a single layer of antireflective film 3 with a thickness of 100 nm is coated on the upper surface of the front glass 2. The first raw material of the antireflective film 3 is magnesium fluoride, and the color masterbatch is made of iron yellow material. The antireflective film 3 exhibits yellow reflected light, so that the overall transmittance of the front glass 2 and the antireflective film 3 is 88%; the front adhesive film 4 is colored with iron yellow material to form a yellow POE film with a transmittance of 87%, forming a photovoltaic structure 1 with a reflectance of 6% on the coated side. The antireflective film 111 has a thickness of 165 mm, and the antireflective film 111 has a refractive index of 165 mm. If the refractive index is 2, then the product of the refractive index and the thickness of the antireflective coating 111 is 330nm. A solar cell is formed through the photovoltaic structure 1; a transparent POE back film 6 with a transmittance of 91% is formed; a transparent glass backsheet 5 is formed; then, based on the sequentially stacked antireflective coating 3, front glass 2, front film 4, solar cell, back film 6, and backsheet 5, a laminate 10 is formed, at which point the front of the laminate 10 appears yellow; a first yellow color layer 8 is sprayed onto the outer surface of the frame 7, and the frame 7 is installed onto the laminate 10 to secure it in place. A second yellow color layer 12 is sprayed onto the outer surface of the junction box 9, and the junction box 9 is installed on the backsheet 5 and electrically connected to the solar cell. At this point, a photovoltaic module with a yellow front is formed.

[0106] For example, the refractive index of magnesium fluoride in the first raw material is 1.38, and the refractive index of the front glass 2 is 1.52. The sequentially increasing refractive index effectively improves the light transmission effect.

[0107] When the combined light transmittance of the front glass 2 and the anti-reflective film 3 is 88%, and the light transmittance of the front yellow film is 87%, and the combined light transmittance after mutual lamination exceeds 85%, the output power of the photovoltaic module can be effectively guaranteed.

[0108] like Figure 5 The present disclosure provides a color-changing photovoltaic module 100, which is manufactured according to the steps of the method 1000 for manufacturing a color-changing photovoltaic module described above.

[0109] The color-changing photovoltaic module 100 provided in this embodiment changes the color while compensating for power generation efficiency.

[0110] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0111] The above-described various forms of processes can be used, and steps can be reordered, added, or deleted. The steps described in the embodiments of this disclosure can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution provided by the embodiments of this disclosure can be achieved, and no limitation is imposed herein.

[0112] The embodiments described above are merely illustrative of several implementations of this disclosure, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the disclosed patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this disclosure, and these all fall within the protection scope of this disclosure. Therefore, the protection scope of this patent should be determined by the appended claims.

Claims

1. A method for manufacturing color-changing photovoltaic modules, characterized in that, include: A silicon wafer is texturized, diffused, and coated to form a photovoltaic structure, wherein the reflectivity of the coated side of the photovoltaic structure ranges from 3% to 10%. The photovoltaic structure forms the solar cell; An antireflective coating with a thickness ranging from 50 nm to 220 nm is applied to the front glass; and The antireflective film, the front glass, the front adhesive film, and the battery cell are stacked sequentially using a front adhesive film with a light transmittance greater than or equal to 80%.

2. The method for manufacturing color-changing photovoltaic modules according to claim 1, characterized in that, The coating step includes: depositing an antireflective film, wherein the product of the refractive index of the antireflective film and the thickness of the antireflective film is in the range of 80 nm to 160 nm, or 260 nm to 440 nm.

3. The method for manufacturing color-changing photovoltaic modules according to claim 2, characterized in that, The method further includes: forming the front glass, wherein the step of forming the front glass includes: forming ultra-clear glass through a float glass production process or a patterned glass production process; and acid etching the ultra-clear glass.

4. The method for manufacturing color-changing photovoltaic modules according to claim 3, characterized in that, The steps of forming the front adhesive film include: forming a colorless front adhesive film; or forming a front adhesive film based on a second raw material including pigments.

5. The method for manufacturing color-changing photovoltaic modules according to claim 4, characterized in that, The method further includes: forming a back panel made of transparent glass or opaque sheet material; Forming a backing film of transparent or opaque material; A laminate is formed based on the stacked antireflective film, the front glass, the front adhesive film, the battery cell, the back adhesive film, and the back sheet; A first color layer is formed on the surface of the border; The laminate is framed within the border; and A second colored layer is formed on the surface of the junction box, the junction box is installed on the back plate, and the junction box is electrically connected to the battery cell.

6. The method for manufacturing color-changing photovoltaic modules according to claim 5, characterized in that, The antireflective coating has a coating thickness of 90 nm; A front-side adhesive film with a first color and a light transmittance of 87% is formed; The antireflection film is formed with a refractive index and film thickness product of 90 nm. The photovoltaic structure having a reflectivity of 6% on the coated side; The back adhesive film is formed from a transparent material with a light transmittance of 91%. The backplate is formed of transparent glass material; as well as A first colored layer having the first color is formed on the surface of the border.

7. The method for manufacturing color-changing photovoltaic modules according to claim 5, characterized in that, An antireflective coating with a thickness of 90 nm; The front adhesive film is formed from a transparent material with a light transmittance of 91%. The antireflection film is formed with a refractive index and film thickness product of 90 nm. The photovoltaic structure having a reflectivity of 6% on the coated side; A second-color backing film with 60% light transmittance is formed; To form a back panel made of transparent glass; A first colored layer having the second color is formed on the surface of the border; as well as A second colored layer having the second color is formed on the surface of the junction box.

8. The method for manufacturing color-changing photovoltaic modules according to claim 5, characterized in that, An antireflective coating with a thickness of 100 nm is applied, resulting in a transmittance of 88% for the front glass and the antireflective coating. The front adhesive film with a third color and a light transmittance of 87% is formed; The antireflection film is formed with a refractive index and film thickness product of 330 nm. The photovoltaic structure having a reflectivity of 6% on the coated side; The back adhesive film is formed from a transparent material with a light transmittance of 91%. To form a back panel made of transparent glass; A first color layer having the third color is formed on the surface of the border; and A second colored layer having the third color is formed on the surface of the junction box.

9. The method for manufacturing color-changing photovoltaic modules according to claim 1, characterized in that, The steps for forming the solar cell include: performing electrode printing and sintering processes on the photovoltaic structure.

10. A color-changing photovoltaic module, characterized in that, It is manufactured according to the steps of the method for manufacturing color-changing photovoltaic modules as described in any one of claims 1 to 9.

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