Manufacturing process of slate-imitating photovoltaic tile assembly and slate-imitating photovoltaic tile assembly

Abstract

The invention belongs to the technical field of slate-imitating photovoltaic tile assemblies for buildings, and discloses a manufacturing process of a slate-imitating photovoltaic tile assembly and the slate-imitating photovoltaic tile assembly. The manufacturing process of the slate-imitating photovoltaic tile assembly comprises the following steps: printing a slate-imitating texture pattern on one side, close to a photovoltaic battery piece, of high-permeability glass according to a screen printing plate by adopting high-temperature printing ink, and manufacturing an upper cover plate of the slate-imitating photovoltaic tile assembly; wherein at least one layer of slate texture imitating patterns is printed on the high-permeability glass; after each layer of slate-imitating texture pattern is printed, drying is conducted; after the multiple layers of slate-imitating texture patterns are printed in sequence, the high-permeability glass printed with the slate-imitating texture patterns is placed in a toughening furnace to be subjected to heat treatment. According to the invention, the slate-texture-imitating pattern is printed on the inner side of the glass and is wrapped by the adhesive film, so that the pattern, the glass and the battery piece form a stable integrated structure, and the aesthetic fusion degree of the photovoltaic module and the building environment and the weather resistance of the pattern are greatly improved.

Description

Technical Field

[0001] This invention belongs to the technical field of architectural imitation slate photovoltaic tile modules. Specifically, it relates to a manufacturing process for an imitation slate photovoltaic tile module and an imitation slate photovoltaic tile module. Background Technology

[0002] Building-integrated photovoltaics (BIPV) technology is developing rapidly, and photovoltaic tiles, which combine energy conversion and roofing functions, are widely used in residential and public buildings. However, existing photovoltaic tile products are mostly dark-colored and monotonous with grid patterns, which are difficult to integrate with traditional architectural aesthetics, especially in building complexes where slate tiles are used as a uniform decoration, resulting in a noticeable sense of incongruity.

[0003] Slate tiles are a traditional European roofing material with a history of over a thousand years. They still hold an important place in the roofing materials of European countries such as the UK, Germany, France, and Spain, especially in important public buildings like churches, palaces, and museums, as well as luxurious private villas. In recent years, slate has also been used by architects for the roofs and exterior walls of many modern buildings, making it a widely popular exterior decoration material. However, current photovoltaic (PV) tiles differ significantly in appearance from slate tiles, making them difficult to integrate with slate roofs. Some PV tile products have attempted to improve the appearance of the photovoltaic glass by printing patterns onto the outside. However, this approach remains purely decorative and lacks a true reproduction of the texture, color, and light and shadow of natural slate tiles. Furthermore, some printed patterns cause significant shading of the solar cells, reducing the light transmittance of the photovoltaic glass, limiting the power generation efficiency of the cells, and potentially even causing hot spots, affecting the lifespan of the PV tile modules. In practical use, the patterns also exhibit low weather resistance, leading to fading and peeling.

[0004] Therefore, there is an urgent need to provide a manufacturing process for the top cover of a slate-look photovoltaic tile module with better power generation performance, stronger weather resistance, and higher environmental compatibility, as well as a slate-look photovoltaic tile module itself, to solve the above problems.

[0005] In view of the above, this application is hereby submitted. Summary of the Invention

[0006] The technical problem to be solved by this invention is to overcome the shortcomings of existing slate photovoltaic tile modules, such as poor power generation performance, weak weather resistance, and low environmental compatibility. The purpose is to provide a manufacturing process for the top cover plate of a slate photovoltaic tile module with better power generation performance, stronger weather resistance, and higher environmental compatibility.

[0007] Another object of the present invention is to provide a slate-like photovoltaic tile module with a top cover plate manufactured using the above-described manufacturing process.

[0008] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by the present invention is: a manufacturing process for a slate-like photovoltaic tile module, wherein the slate-like photovoltaic tile module includes a top cover plate and photovoltaic cells, and the manufacturing process includes: in a dust-free environment, using high-temperature ink or low-temperature ink, printing the slate-like texture pattern on a screen onto the side of a high-transparency glass facing closer to the photovoltaic cells, thereby obtaining the top cover plate of the slate-like photovoltaic module, or...

[0009] In a dust-free environment, a UV flatbed printer is used to print a slate-like texture pattern onto the side of a high-transparency glass facing the photovoltaic cell, thereby producing the top cover of the slate-like photovoltaic module.

[0010] The top cover plate is fixedly connected to the photovoltaic cell by an adhesive film; the imitation slate texture pattern is wrapped inside the adhesive film;

[0011] The slate-like texture pattern is printed on the high-transparency glass in at least one layer.

[0012] High-transparency glass printed with imitation slate texture patterns using low-temperature ink printing or UV flatbed printing. After each layer of imitation slate texture pattern is printed, it is dried by ultraviolet irradiation.

[0013] High-transparency glass printed with imitation slate texture patterns using high-temperature ink is dried at room temperature after each layer of imitation slate texture pattern is printed. After multiple layers of imitation slate texture patterns are printed in sequence, the high-transparency glass with imitation slate texture patterns printed with high-temperature ink is placed in a tempering furnace for heat treatment.

[0014] According to one embodiment of the present invention, the fabrication of the screen printing stencil includes:

[0015] S1. Acquire raw display images of slate tile samples under soft light conditions;

[0016] S2. The acquired raw display image is desaturated, noise is optimized, and converted into a dot matrix structure;

[0017] S3. Extract the morphological information of the particle region in the lattice structure, and reconstruct the particle region into a dot pattern.

[0018] S4. Based on the layering results of the generated dot pattern, use a photosensitive screen to create a single-layer or multi-layer monochrome screen printing stencil.

[0019] According to one embodiment of the present invention, the converted lattice structure includes slate texture information and edge contour information;

[0020] The slate texture information and edge contour information are extracted as morphological information of the particle region in step S3.

[0021] According to one embodiment of the present invention, the diameter of the dots in the generated dot pattern is 0.1mm-1.2mm.

[0022] According to one embodiment of the present invention, the mesh size of the monochrome screen printing stencil is 200-350 meshes / inch.

[0023] According to one embodiment of the present invention, the high-transparency glass is subjected to acid washing and anti-reflection treatment before the imitation slate texture pattern is printed on the high-transparency glass.

[0024] According to one embodiment of the present invention, when it is necessary to use multi-layer monochrome screen printing stencils to print the imitation slate texture pattern onto the high-transparency glass through multi-layer printing, the ceramic inks used on adjacent monochrome screen printing stencils may be the same or different in color.

[0025] According to one embodiment of the present invention, the high-transparency glass printed with a slate-like texture pattern using high-temperature ink is heat-treated in a tempering furnace at a tempering temperature of 650-760°C.

[0026] The present invention also provides a slate-look photovoltaic tile module, including an upper cover plate manufactured using the above-mentioned manufacturing process of a slate-look photovoltaic tile module;

[0027] The slate-like photovoltaic tile module also includes:

[0028] The lower back plate is connected to the side of the photovoltaic cell away from the upper cover plate by an adhesive film.

[0029] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0030] 1) In this invention, under dust-free conditions, high-temperature ink, low-temperature ink screen printing, or UV flatbed printing technology is used to print a slate-like texture pattern onto the side of high-transparency glass facing the photovoltaic cells. This design fundamentally improves the appearance of photovoltaic tiles. Compared to existing technologies that only print patterns on the outside of the photovoltaic glass, resulting in a single decorative layer, this invention prints the slate-like texture pattern on the inside of the glass and wraps it with an adhesive film, creating a stable integrated structure between the pattern, glass, and solar cells. In practical applications, the color, texture, and light and shadow effects can realistically reproduce the texture of natural slate tiles, effectively solving the problem of incompatibility and disharmony between existing photovoltaic tiles and traditional slate tile roofs, and significantly improving the aesthetic integration of photovoltaic modules with the building environment.

[0031] 2) Existing pattern printing methods often cause large-area shading of the solar cells, leading to reduced light transmittance of the photovoltaic glass, which in turn limits the power generation efficiency of the cells and may even cause hot spot effects. This invention uses high-transmittance glass as the top cover and prints a slate-like texture pattern on the side closest to the solar cells. Through reasonable process control, the pattern presentation is ensured while minimizing the impact on light transmission. Simultaneously, standardized drying processes (low-temperature ink or UV printing followed by UV irradiation drying, high-temperature ink printing followed by room temperature drying and tempering furnace heat treatment) ensure that the pattern adheres firmly to the glass surface, preventing ink buildup or uneven drying from affecting light transmittance. This ensures that the photovoltaic cells can fully receive sunlight, effectively improving the power generation performance of the photovoltaic modules and avoiding problems such as decreased power generation efficiency and shortened module lifespan caused by pattern printing.

[0032] 3) Existing technologies suffer from low weather resistance and easy fading and peeling of patterns. In this invention, the slate-like texture pattern is encased in an adhesive film. This film not only serves to fix the top cover plate and photovoltaic cells but also provides a physical protective barrier for the pattern, shielding it from direct environmental factors (such as ultraviolet radiation, rain erosion, and wind and sand abrasion). Furthermore, the drying processes for different ink types, especially the tempering furnace heat treatment after high-temperature ink printing, further enhance the bonding strength between the pattern and the glass. This allows the pattern to remain stable in complex and changing outdoor environments for a long time, effectively overcoming the problem of poor pattern durability in existing technologies and significantly improving the weather resistance and service life of the slate-like photovoltaic tile module.

[0033] The specific embodiments of the present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0034] The accompanying drawings, as part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention, but do not constitute an undue limitation of the invention. Obviously, the drawings described below are merely some embodiments, and those skilled in the art can obtain other drawings based on these drawings without creative effort. In the drawings:

[0035] Figure 1 This is a flowchart illustrating the steps involved in creating a screen printing stencil in an embodiment of the present invention.

[0036] Figure 2 This is a visual representation of the monochrome screen printing stencil in an embodiment of the present invention;

[0037] Figure 3 This is an external view of the photovoltaic module in an embodiment of the present invention;

[0038] Figure 4This is a power test diagram of the finished product sample extracted in an embodiment of the present invention;

[0039] Figure 5 This is a power test data table of the finished product samples extracted in the embodiments of the present invention.

[0040] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0042] In the description of this invention, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0043] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0044] like Figures 1 to 5 As shown, the present invention discloses a manufacturing process for a slate-look photovoltaic tile module, the slate-look photovoltaic tile module comprising a top cover plate and photovoltaic cells, the manufacturing process comprising:

[0045] In a dust-free environment, using high-temperature or low-temperature ink, the imitation slate texture pattern on the screen is printed onto the side of high-transparency glass facing closer to the photovoltaic cells to obtain the top cover plate of the imitation slate photovoltaic module. Alternatively, in a dust-free environment, using a UV flatbed printer, the imitation slate texture pattern is printed onto the side of high-transparency glass facing closer to the photovoltaic cells to obtain the top cover plate of the imitation slate photovoltaic module.

[0046] The top cover plate is fixedly connected to the photovoltaic cell by an adhesive film; the imitation slate texture pattern is wrapped inside the adhesive film;

[0047] The slate-like texture pattern is printed on at least one layer of the high-transparency glass.

[0048] High-transparency glass printed with imitation slate texture patterns using low-temperature ink printing or UV flatbed printing. After each layer of imitation slate texture pattern is printed, it is dried by ultraviolet irradiation.

[0049] High-transparency glass printed with imitation slate texture patterns using high-temperature ink is dried at room temperature after each layer of imitation slate texture pattern is printed. After multiple layers of imitation slate texture patterns are printed in sequence, the high-transparency glass with imitation slate texture patterns printed with high-temperature ink is placed in a tempering furnace for heat treatment.

[0050] In this invention, under dust-free conditions, high-temperature ink, low-temperature ink screen printing, or UV flatbed printing technology are used to print a slate-like texture pattern onto the side of high-transparency glass facing the photovoltaic cells. This design fundamentally improves the appearance of photovoltaic tiles. Compared to existing technologies that only print patterns on the outside of the photovoltaic glass, resulting in a single decorative layer, this invention prints the slate-like texture pattern on the inside of the glass and wraps it with an adhesive film, creating a stable integrated structure between the pattern, glass, and solar cells. In practical applications, the color, texture, and light and shadow effects realistically reproduce the feel of natural slate tiles, effectively solving the problem of incompatibility and disharmony between existing photovoltaic tiles and traditional slate tile roofs, and significantly improving the aesthetic integration of photovoltaic modules with the building environment.

[0051] From a power generation performance perspective, some existing pattern printing solutions cause large-area shading of the solar cells, leading to reduced light transmittance of the photovoltaic glass, which in turn limits the power generation efficiency of the solar cells and may even cause hot spot effects. This invention uses high-transmittance glass as the top cover and prints a slate-like texture pattern on the side closest to the solar cells. Through reasonable process control, the pattern presentation is ensured while minimizing the impact on light transmission. Simultaneously, standardized drying processes (low-temperature ink or UV printing followed by UV irradiation drying, high-temperature ink printing followed by room temperature drying and tempering furnace heat treatment) ensure that the pattern adheres firmly to the glass surface, preventing ink buildup or uneven drying from affecting light transmittance. This ensures that the photovoltaic cells can fully receive sunlight, thereby effectively improving the power generation performance of the photovoltaic modules and avoiding problems such as decreased power generation efficiency and shortened module lifespan caused by pattern printing.

[0052] Regarding weather resistance, existing technologies suffer from low pattern weather resistance and easy fading and peeling. In this invention, the slate-like texture pattern is encased in an adhesive film. This film not only serves to fix the top cover plate and photovoltaic cells but also provides a physical protective barrier for the pattern, shielding it from the direct impact of external environmental factors (such as ultraviolet radiation, rain erosion, and wind and sand abrasion). Furthermore, the drying processes for different ink types, especially the tempering furnace heat treatment after high-temperature ink printing, further enhance the bonding strength between the pattern and the glass. This allows the pattern to remain stable in complex and changing outdoor environments for a long time, effectively overcoming the problem of poor pattern durability in existing technologies and significantly improving the weather resistance and service life of the slate-like photovoltaic tile module.

[0053] It should be noted that the screen printing does not produce an image of slate, but rather the natural texture of slate and the points that determine the distribution of color grayscale. The screen printing alone, or the imitation slate texture pattern printed by multiple screen printing layers, cannot form an image of slate. Only when the top cover plate with the imitation slate texture pattern is printed in conjunction with the photovoltaic cells and the (black) bottom back plate, can the slate image be formed.

[0054] In one specific embodiment of this example, the light transmittance of the high-transmittance glass is 96%-98%.

[0055] In one specific implementation of this embodiment, "in a cleanroom" means placed in a cleanroom printing room.

[0056] In one specific embodiment of this example, drying the high-transparency glass printed with a slate-like texture pattern using high-temperature ink in an environment at or above room temperature includes: drying at room temperature or baking at a medium temperature to preliminarily solidify and shape the printed pattern color layer and prevent overlapping between adjacent color layers.

[0057] In one specific implementation of this embodiment, the ambient temperature environment refers to the room temperature environment, which is usually 15℃-30℃.

[0058] In one specific implementation of this embodiment, the medium-temperature environment refers to an environment of 100°C.

[0059] The curing and setting time of ink is affected by actual temperature and humidity, so there is no specific time limit. In practical applications, the curing and setting time is determined by observation and testing.

[0060] Low-temperature inks require lower curing temperatures compared to high-temperature inks. Furthermore, low-temperature inks offer vibrant colors, making them suitable for visually appealing building materials. However, in terms of weather resistance, low-temperature inks are not as durable as high-temperature inks.

[0061] UV flatbed printing, compared to screen printing, can produce more detailed patterns. When mass production is required, multiple UV printers are needed. UV printing is far less efficient and costly than screen printing. However, it can be used for small quantities because it does not require the creation of screens, resulting in lower production costs.

[0062] Therefore, the three methods (printing and printing) provided in this application can be selected according to the actual application.

[0063] Method for printing slate-like texture patterns using a UV printer:

[0064] Take photos of real slate samples, optimize the patterns, and convert them to CMYK mode. Import the processed images into UV printer software, set the print size (depending on the components you are making), and resolution (300dpi). To enhance the expressiveness of the pattern, you can add white ink below the color layers to make the colors more saturated.

[0065] Before printing, you need to adjust the height of the printer platform so that the height difference between the print head and the glass surface is about 1-2mm. Before printing, apply a layer of glass cleaner to the glass, place the glass on the printer platform, adjust the position, and you can start printing.

[0066] When printing, a UV lamp should be turned on to irradiate the glass, allowing the ink to dry and fix onto the glass surface.

[0067] Please see the appendix Figure 1 In one specific embodiment of this example, the fabrication of the screen printing stencil includes:

[0068] S1. Acquire raw display images of slate tile samples under soft light (soft, low-contrast scattered light) conditions;

[0069] S2. The acquired raw display image is desaturated, noise is optimized, and converted into a dot matrix structure;

[0070] S3. Extract the morphological information of the particle region in the lattice structure, and reconstruct the particle region into a dot pattern.

[0071] S4. Based on the layering results of the generated dot pattern, use a photosensitive screen to create a single-layer or multi-layer monochrome screen printing stencil.

[0072] By applying the screen printing stencil in the manufacturing process of the slate-like photovoltaic tile module provided in this application, a highly realistic slate texture pattern printing stencil is generated based on a real high-resolution image of slate. This makes the texture and layers of the slate-like photovoltaic tile module closer to natural stone, improving its integration with the building and its aesthetics.

[0073] In one specific embodiment of this example, step S1 specifically includes: selecting a typical slate sample, and under soft light conditions (uniform and gentle light, without direct light), acquiring a roof image (original display image) using a high-resolution photographic device to ensure that the texture and particle features of the slate tile are clearly visible in the acquired roof image.

[0074] In one specific implementation of this embodiment, step S2 specifically includes: importing the acquired roof image (including color) into image processing software (using AI image analysis tools, texture transfer algorithms, etc.), performing desaturation grayscale processing, extracting its typical grayscale texture (such as natural deposition marks, linear cracks, etc.), retaining only black and white grayscale information, strengthening the light and dark contrast relationship of the tile surface particles, and converting the image into a dot matrix structure.

[0075] In step S2, the original aspect ratio of the acquired original display image is maintained without stretching or scaling; the original display details of the image are not changed, and the display of the surface full of particles is preserved.

[0076] In step S2, the size and density of the control points are used to simulate the light and dark relationships in the image, so that the final effect is closer to what the naked eye sees.

[0077] Specifically, because the photovoltaic cells are blackish-blue, other colors are printed on the glass surface, and these colors are superimposed on the blackish-blue to form the simulated slate texture pattern. The black areas visible to the naked eye, i.e., the shadow areas, are not processed; instead, they are displayed using the color of the photovoltaic cells themselves. For example, the image is processed with gray-white dots to represent the bright areas.

[0078] In one specific embodiment of this invention, the imitation slate photovoltaic tile module is stacked one layer on top of another, which actually creates shadows, a sense of thickness, and texture. Therefore, during image processing, the shadows at the overlapping areas of these tiles are also represented, using white, dark gray, or black to reproduce this "texture." White ceramic ink is screen-printed onto the inner surface of the glass (the side facing the photovoltaic cells), presenting a low-saturation natural gray tone against a black background without grid lines, achieving a visual color mixing effect. This makes the pattern printed on the glass look more realistic and spatial, creating a genuine sense of texture.

[0079] More specifically, step S2, which involves desaturating the acquired original display image and converting it into a dot matrix structure, includes:

[0080] Image grayscale conversion converts the acquired original display image (removing color information and retaining only the brightness and darkness) into a grayscale image.

[0081] Establish a grid (dot matrix) logic to divide the image into regular small grids (e.g., each unit is 10 pixels × 10 pixels), and extract the corresponding brightness / grayscale value (0~255) for each grid region;

[0082] The darker the area, the higher its corresponding grayscale value;

[0083] The darkest part is the part with the highest grayscale in the image, and the brightest highlight part is the part with the lowest grayscale in the image. The part in between is the texture direction of the slate.

[0084] Brightness is mapped to dot size, generating dots of different sizes for each grayscale region in the image based on the intensity of brightness; dark regions generate smaller dots (or no dots), and bright regions generate larger dots.

[0085] The generated dot matrix structure results in a pattern composed of dots of different sizes, with the dots arranged relatively independently and at intervals.

[0086] In one specific implementation of this embodiment, step S3 specifically includes: converting the image into a bitmap structure, using image algorithms such as filters, thresholding, and edge recognition to extract the morphological information of the particle portion in the image. Combining manual adjustments and automated software scripts, the particle region is reconstructed using point-like abstraction.

[0087] In this application, a dotted abstract composition method is adopted, which preserves sufficient light transmission channels while restoring the visual effect, effectively suppressing the hot spot effect and ensuring power generation efficiency.

[0088] More specifically, including:

[0089] After selecting the granular region and completing grayscale conversion and contrast adjustment, extract the regions corresponding to the grayscale values ​​in the image. These regions are the granular textured parts of the slate tile.

[0090] Image denoising and morphology optimization: using the "blur" function to remove some meaningless high-frequency noise while preserving the overall outline of the particles;

[0091] Dot-matrix processing (dot matrix reconstruction) converts the grayscale of the granular region into a dot matrix format using software.

[0092] In one specific embodiment of this example, step S4 specifically includes: exporting the generated dot pattern as a vector format or a high-precision bitmap file for use in creating a screen printing stencil;

[0093] The (dotted) pattern structure maintains the visual effect of the natural distribution of the tile surface particles within the visible range, while the background area remains blank to improve light transmittance and avoid the effect of blocking heat spots.

[0094] In this application, the above operations help to identify and extract the texture and particle morphology of the slate tile surface. Subsequently, combined with image vectorization processing, the extracted particle edges are converted into a dot matrix distribution structure. By controlling the size and density of the dots, a high-fidelity pattern suitable for screen printing is constructed.

[0095] More specifically, the need to create multiple screen printing plates depends on the actual color composition of the slate tile. If it is blackish-gray, no layering is required, and one screen printing plate is sufficient; if it is colored (with multiple colors, such as white, gray, and black), layering is required, and multiple (two or more) screen printing plates need to be created.

[0096] To create the texture and layers of slate.

[0097] In one specific implementation of this embodiment, the method further includes the following step before step S2:

[0098] Detect the colors contained in the acquired raw display image;

[0099] If the original display image is detected to contain only black and gray colors, then proceed to step S2; if the original display image is detected to contain colors other than black and gray, then no grayscale processing is performed, and it is directly converted into a dot matrix structure.

[0100] The subsequent steps S3 and S4 are run in sequence; in step S4, different layers are distinguished according to different colors, which are used to create corresponding multi-layer monochrome screen printing stencils.

[0101] In one specific implementation of this embodiment, the converted lattice structure includes slate texture information and edge contour information;

[0102] The slate texture information and edge contour information are extracted as "morphological information of the grain region" in step S3;

[0103] By preserving its original irregular edge features, the final screen-printed pattern boundary exhibits a natural, non-linear characteristic, more closely resembling the visual effect of real slate.

[0104] In the established mesh, the edges of the pattern are identified as the outline of the slate texture edge. Based on this identification, the texture outline is determined, and a dotted pattern is generated.

[0105] In one specific embodiment of this example, the outline of the identified slate texture edge is further processed to remove obviously broken pattern edges.

[0106] In one specific implementation of this embodiment, the "morphological information of the granular region" in step S3 includes detailed features such as the distribution, outline, thickness, and orientation of the granular region in the slate tile image.

[0107] In one specific embodiment of this example, the diameter of the generated dot pattern is 0.1mm-1.2mm;

[0108] The distance and density between dots are adaptively adjusted according to the light and dark distribution on the tile surface to ensure clear pattern reproduction while minimizing light obstruction.

[0109] It retains the sense of texture direction while also having good light transmission gaps.

[0110] The density of points in the bright areas is low, and the distance between adjacent points is large.

[0111] Dark areas have a high density of points and small distances between adjacent points.

[0112] In this invention, by defining the dot pattern, the ink coverage during the printing process is controlled, ensuring that the pattern is clear but does not block light in patches, so that the light-transmitting area of ​​the printed pattern is uniform and there is no obvious ink overflow or jagged edges.

[0113] The screen printing pattern is made using positive film exposure and exposed using a UV exposure machine to ensure clear edges of the pattern.

[0114] Please refer to the appendix for the appearance of the monochrome screen printing stencil. Figure 2 .

[0115] In one specific embodiment of this example, the mesh size of the monochrome screen printing stencil is 200-350 meshes / inch;

[0116] Polyester mesh is used with a mesh tension of 22-25N to ensure printing accuracy and print count.

[0117] In one specific implementation of this embodiment, each screen is marked with a serial number corresponding to its color layer, which facilitates the subsequent control of the printing sequence according to its color layer serial number.

[0118] In one specific embodiment of this example, before the imitation slate texture pattern is printed on the high-transparency glass, the entire high-transparency glass undergoes acid washing and anti-reflection treatment.

[0119] After the acid washing and anti-reflection treatment is completed, the product is thoroughly cleaned and dried, and then placed in a dust-free printing room to await the printing of the pattern color layers.

[0120] In this invention, the glass undergoes acid washing, resulting in a slightly rough surface structure. This effectively reduces surface reflection and enhances the adhesion of the pattern. Untreated glass surfaces have strong reflections, which can cause the pattern to disappear or become unclear when viewed at an angle due to the high brightness of the reflected pattern. By improving the acid washing and polishing processes, the glass surface maintains high light transmittance while controlling the reflection angle to reduce glass reflection. This ensures that the photovoltaic module presents a perfect visual effect of the pattern from various angles. This achieves the goal of meeting the requirements of high light transmittance of the power generation surface, improving power generation efficiency, and conforming to architectural aesthetics and anti-glare requirements, thus reducing urban light pollution.

[0121] In one specific embodiment of this example, the printing method can be selected from manual, semi-automatic, or fully automatic screen printing machines, depending on the printing pattern and size.

[0122] Scraper angle: 60°-75°; Scraper hardness: 75-80A.

[0123] In one specific embodiment of this example, the imitation slate texture pattern is printed on the high-transparency glass in 1-3 layers;

[0124] It is understandable that the number of monochrome screen printing stencils required corresponds to the number of printing layers required.

[0125] In one specific embodiment of this example, when it is necessary to use multi-layer monochrome screen printing stencils to print the imitation slate texture pattern onto the high-transparency glass through multi-layer printing, the ceramic inks used on adjacent monochrome screen printing stencils may be the same or different colors.

[0126] In one specific embodiment of this example, the ceramic ink includes ceramic inks in colors such as white, gray, and brown.

[0127] In this invention, by applying multiple layers of ceramic inks in various colors, it is easier to construct more realistic three-dimensional textures and more realistic (mainly dark-toned) color patterns according to actual designs, thereby improving the aesthetics of photovoltaic tiles and their compatibility with the surrounding environment.

[0128] In one specific embodiment of this example, the thickness of the single-layer printed ceramic ink is 5-25 μm.

[0129] In one specific embodiment of this invention, high-transparency glass printed with a slate-like texture pattern using high-temperature ink undergoes heat treatment in a tempering furnace at a tempering temperature of 650-760℃. This process is used to sinter the ceramic ink and impart weather resistance and strength to the glass. After high-temperature treatment, the pattern is fixed to the inner surface of the glass, and the pattern color is stable, washable, and can be used outdoors for more than 20 years without fading.

[0130] In one specific embodiment of this invention, the high-transparency glass is heat-treated in a tempering furnace at a tempering temperature of 680-730°C.

[0131] The present invention also provides a slate photovoltaic tile module with an upper cover plate manufactured using the above-mentioned manufacturing process of a slate photovoltaic tile module, the slate photovoltaic tile module further comprising:

[0132] The lower back plate is connected to the side of the photovoltaic cell away from the upper cover plate by an adhesive film.

[0133] In this invention, the photovoltaic module formed by applying the aforementioned top cover plate has higher compatibility with the surrounding environment due to the three-dimensional texture presented by the top cover plate; it causes less shading to the photovoltaic cells and has higher power generation efficiency; the pattern isolates the air and has higher stability.

[0134] In one specific embodiment of this example, the photovoltaic cell can be any crystalline silicon cell such as PERC, TOPCon, HJT, or BC, chromium telluride and copper indium gallium selenide thin-film cells, perovskite cells, etc.

[0135] In one specific embodiment of this example, the adhesive film may be an EVA / POE / EPE / PVB adhesive film, etc.

[0136] In one specific embodiment of this invention, the slate-like photovoltaic tile module includes, from top to bottom, an upper cover plate, an encapsulating film, photovoltaic cells, an encapsulating film, and a lower back plate, which are hot-pressed under vacuum and high-temperature conditions using a laminator. Please refer to the appendix. Figure 3 The formed photovoltaic tiles present a textured slate tile pattern with natural colors and three-dimensional texture, and the overall power generation efficiency is no less than 90% of that of bare glass modules.

[0137] In this invention, the pattern is printed on the inner surface of the glass (the side facing the photovoltaic cell) using high-temperature ceramic ink. It is then tempered and cured at high temperature together with the glass. This allows the ink pattern to be encapsulated in the inner layer by the adhesive film (first adhesive film) after the component is laminated, preventing direct contact with the external environment and thus preventing wear and tear on the pattern. This effectively extends the service life, with an actual service life of more than 20 years.

[0138] In one specific implementation of this embodiment, the test results of the finished product sample are as follows:

[0139] Light transmittance test: Light transmittance is above 85%;

[0140] Power generation performance test: Under simulated sunlight, the Pmax reduction was controlled within 5%;

[0141] Adhesion test: The ink passed the adhesion test and did not peel off;

[0142] Weather resistance test: No fading after 1000 hours of UV aging test, and no cracks after 100 cycles of hot and cold shock test.

[0143] To further illustrate the technical effects of this invention, a sample of the finished product was taken. Please refer to the appendix. Figure 4 This is the power test diagram for the finished product sample; please refer to the appendix. Figure 5 This is the power test data for the sample.

[0144] This patent achieves a unified appearance and performance for slate-look photovoltaic tile modules through the combination of pattern structure design and high-temperature screen printing technology. The pattern visually replicates the granular texture of slate tiles, exhibiting excellent three-dimensional layering and textural characteristics. Functionally, the dotted design and ink control effectively manage the shading area, ensuring a light transmittance of over 85% and maintaining high power generation of the photovoltaic modules. Utilizing a high-temperature weather-resistant ink system, the pattern possesses excellent adhesion and UV resistance, meeting the long-term outdoor usage requirements.

[0145] Meanwhile, the proposed solution has good scalability and adaptability, and can be applied to a variety of glass processing methods and cell technology (applicable to all conventional photovoltaic modules, such as aluminum frame single-glass or double-glass modules, framed or frameless photovoltaic tiles and other BIPV integrated photovoltaic module projects), and has obvious innovation, practicality and industrialization potential.

[0146] It should also be pointed out that although this application is about the manufacturing process of imitation slate photovoltaic tiles, it can also be adapted to imitation slate photovoltaic curtain walls and imitation slate floor tiles without any obstacles.

[0147] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present invention. The implementation schemes in the above embodiments can also be further combined or replaced. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A manufacturing process for a slate-look photovoltaic tile module, the slate-look photovoltaic tile module comprising a top cover plate and photovoltaic cells, characterized in that, The manufacturing process includes: in a dust-free environment, using high-temperature or low-temperature ink, printing the slate-like texture pattern from a screen onto the side of a high-transparency glass facing the photovoltaic cell, thereby creating the top cover of the slate-like photovoltaic module, or... In a dust-free environment, a UV flatbed printer is used to print a slate-like texture pattern onto the side of a high-transparency glass facing the photovoltaic cell, thereby producing the top cover of the slate-like photovoltaic module. The top cover plate is fixedly connected to the photovoltaic cell by an adhesive film; the imitation slate texture pattern is wrapped inside the adhesive film; The slate-like texture pattern is printed on the high-transparency glass in at least one layer. High-transparency glass printed with imitation slate texture patterns using low-temperature ink printing or UV flatbed printing. After each layer of imitation slate texture pattern is printed, it is dried by ultraviolet irradiation. High-transparency glass printed with imitation slate texture patterns using high-temperature ink is dried at room temperature after each layer of imitation slate texture pattern is printed. After multiple layers of imitation slate texture patterns are printed in sequence, the high-transparency glass with imitation slate texture patterns printed with high-temperature ink is placed in a tempering furnace for heat treatment.

2. The manufacturing process of a slate-like photovoltaic tile module according to claim 1, characterized in that, The production of the screen printing stencil includes: S1. Acquire raw display images of slate tile samples under soft light conditions; S2. The acquired raw display image is desaturated, noise is optimized, and converted into a dot matrix structure; S3. Extract the morphological information of the particle region in the lattice structure, and reconstruct the particle region into a dot pattern. S4. Based on the layering results of the generated dot pattern, use a photosensitive screen to create a single-layer or multi-layer monochrome screen printing stencil.

3. The manufacturing process of a slate-like photovoltaic tile module according to claim 2, characterized in that, The transformed lattice structure contains slate texture information and edge contour information; The slate texture information and edge contour information are extracted as morphological information of the particle region in step S3.

4. The manufacturing process of a slate-like photovoltaic tile module according to claim 2, characterized in that, The generated dot pattern has a dot diameter of 0.1mm-1.2mm.

5. The manufacturing process of a slate-imitation photovoltaic tile module according to claim 2, characterized in that, The mesh size of the monochrome screen printing stencil is 200-350 meshes / inch.

6. The manufacturing process of a slate-like photovoltaic tile module according to any one of claims 1-5, characterized in that, Before the imitation slate texture pattern is printed on the high-transparency glass, the entire high-transparency glass undergoes acid washing and anti-reflection treatment.

7. The manufacturing process of a slate-imitation photovoltaic tile module according to claim 6, characterized in that, When it is necessary to use multi-layer monochrome screen printing stencils to print imitation slate texture patterns onto the high-transparency glass through multi-layer printing, the ceramic inks used on adjacent monochrome screen printing stencils may be the same or different colors.

8. The manufacturing process of a slate-like photovoltaic tile module according to claim 6, characterized in that, High-transparency glass printed with slate-like texture patterns using high-temperature ink is heat-treated in a tempering furnace at a tempering temperature of 650-760℃.

9. A slate-inspired photovoltaic tile module, characterized in that, The assembly includes a top cover plate manufactured using the manufacturing process of a slate-look photovoltaic tile module according to any one of claims 1-8, and the slate-look photovoltaic tile module further includes: The lower back plate is connected to the side of the photovoltaic cell away from the upper cover plate by an adhesive film.

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