A manufacturing process of an upper cover plate of a tile-shaped photovoltaic module and a tile-shaped photovoltaic module

Abstract

The application belongs to the technical field of imitative tile type photovoltaic module for building, and discloses a manufacturing process of an upper cover plate of an imitative tile type photovoltaic module and the imitative tile type photovoltaic module. The manufacturing process of the upper cover plate of the imitative tile type photovoltaic module comprises the following steps: in a dust-free environment, an imitative tile type pattern is printed on the inner side of high-transparency glass according to a silk screen printing screen or a UV flat plate to obtain the upper cover plate of the imitative tile type photovoltaic module; wherein after the single-layer imitative asphalt tile / imitative colorful stone metal tile pattern is printed, drying is performed on the pattern in an environment greater than or equal to room temperature, or the pattern is irradiated by a UV lamp. According to the application, the granules and textures of asphalt tiles / colorful stone metal tiles can be better simulated through the superposition of multiple patterns, so that the realness and three-dimensional granular feeling of the pattern are enhanced, and the texture and details of traditional roofing materials are restored.

Description

Technical Field

[0001] This invention belongs to the technical field of building-use imitation tile photovoltaic modules. Specifically, it relates to a manufacturing process of the top cover plate of an imitation tile photovoltaic module and the imitation tile photovoltaic module itself. Background Technology

[0002] Asphalt shingles / stone-coated metal roofing tiles are a globally accepted mainstream roofing material and a representative roofing material for North American-style residential buildings. To make full use of roof space and reduce reliance on non-renewable energy sources, many regions are using photovoltaic tiles instead of ordinary roofing tiles for roof installation.

[0003] Existing photovoltaic (PV) tiles on the market primarily focus on power generation performance in practical applications, but they still have significant shortcomings in terms of appearance. Especially when integrated with traditional asphalt shingles / stone-coated metal roofing, existing PV tile products are mostly single-color blocks or smooth surfaces, making them difficult to integrate with surrounding roofs and affecting the overall aesthetics of the building. Some designs attempt to improve aesthetics by printing patterns on the glass surface of PV tiles, but these generally suffer from severe shading and low light transmittance, thus affecting the normal power generation efficiency of the photovoltaic cells. Furthermore, because the patterns continuously obstruct the cells over large areas, they can easily lead to the "hot spot effect," affecting the safety and lifespan of the PV tiles. At the same time, most existing patterns are two-dimensional, lacking realism and three-dimensional texture, and do not possess the texture and detail reproduction capabilities of traditional roofing materials. In actual use, the patterns have low weather resistance, resulting in fading and peeling.

[0004] Therefore, there is an urgent need to provide a manufacturing process for the cover plate of a tile-shaped photovoltaic module with better power generation performance, stronger weather resistance, and higher environmental compatibility, as well as a tile-shaped photovoltaic 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 technologies, 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 tile-shaped photovoltaic module with better power generation performance, stronger weather resistance, and higher environmental compatibility.

[0007] Another objective of this invention is to provide a roof-type photovoltaic module with a roof cover manufactured using the above-mentioned manufacturing process for a roof-type photovoltaic module.

[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 the top cover plate of a tile-shaped photovoltaic module, comprising: in a dust-free environment, using high-temperature ceramic ink and low-temperature ink, printing a tile-shaped pattern (imitating asphalt shingle pattern or imitation colored stone metal tile pattern) onto the inner surface of a high-transparency glass according to a screen printing stencil, thereby obtaining the top cover plate of the tile-shaped photovoltaic module, or...

[0009] In a dust-free environment, a UV flatbed printer is used to print a tile-shaped pattern onto the inner side of a high-transparency glass to produce the top cover of the tile-shaped photovoltaic module.

[0010] The imitation tile pattern is an imitation asphalt shingle pattern or an imitation colored stone metal tile pattern; the imitation tile pattern is printed on the high-transparency glass in at least one layer;

[0011] High-transparency glass printed with imitation tile patterns using low-temperature ink printing or UV flatbed printing. After each layer of imitation tile pattern is printed, it is dried by ultraviolet irradiation.

[0012] High-transparency glass printed with imitation tile patterns using high-temperature ink is dried at room temperature after each layer of imitation tile pattern is printed. After multiple layers of imitation tile patterns are printed in sequence, the high-transparency glass with imitation tile patterns printed with high-temperature ink is heat-treated in a tempering furnace.

[0013] According to one embodiment of the present invention, the fabrication of the screen printing stencil includes the following steps:

[0014] S1. Collect the original display image of the asphalt shingle sample or colored stone metal tile sample under natural light conditions;

[0015] S2. Desaturate the acquired raw display image and convert it into a bitmap structure;

[0016] S3. Extract the morphological information of the particle region in the lattice structure, and reconstruct the particle region into a dot pattern.

[0017] 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.

[0018] According to one embodiment of the present invention, the diameter of the dots in the generated dot pattern is 0.1mm-1.2mm.

[0019] According to one embodiment of the present invention, the monochrome screen printing stencil has a mesh size of 200-350 meshes / inch, uses polyester mesh, and has a mesh tension of 22-25N.

[0020] According to one embodiment of the present invention, before printing the imitation tile pattern (imitation asphalt shingle pattern or imitation colored stone metal tile pattern) onto the high-transparency glass, the entire high-transparency glass or at least the outer surface of the high-transparency glass is subjected to acid washing and anti-reflection treatment.

[0021] According to one embodiment of the present invention, the number of layers of the imitation tile pattern printed on the high-transparency glass is 1-3; the number of required monochrome screen printing stencils corresponds to the number of printing layers.

[0022] According to one embodiment of the present invention, when it is necessary to use a multi-layer monochrome screen printing stencil to print a tile-shaped 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.

[0023] According to one embodiment of the present invention, the high-transparency glass printed with a tile-shaped pattern using high-temperature ink is heat-treated in a tempering furnace at a tempering temperature of 650-760°C.

[0024] The present invention also provides a roof tile-shaped photovoltaic module, comprising a top cover plate manufactured using the above-described manufacturing process for a roof tile-shaped photovoltaic module, wherein the roof tile-shaped photovoltaic module further comprises:

[0025] A photovoltaic cell, wherein the photovoltaic cell is disposed on the inside of the high-transparency glass near the top cover plate;

[0026] A first adhesive film connects the upper cover plate to the photovoltaic cell.

[0027] A lower back plate is disposed on the side of the photovoltaic cell away from the upper cover plate;

[0028] The second adhesive film connects the lower back sheet to the photovoltaic cell.

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

[0030] This invention simulates the texture and appearance of asphalt shingles, ensuring that photovoltaic tiles (photovoltaic modules) maintain a consistent style with traditional asphalt shingle / stone-coated metal roofing, effectively solving the problem of incompatibility and enhancing the overall aesthetics and environmental adaptability of the building. The process utilizes a monochrome screen printing stencil combined with high-transparency glass, allowing for precise pattern control and preventing large-area continuous shading of the solar cells. This achieves decorative patterns while minimizing the impact on photovoltaic cell power generation, thus improving power efficiency. The layering of multiple patterns better simulates the particles and texture of asphalt shingles / stone-coated metal roofing, enhancing the realism and three-dimensional granular feel of the patterns and restoring the texture and details of traditional roofing materials. Ceramic ink is used, possessing excellent high-temperature resistance, chemical corrosion resistance, and weather resistance. Furthermore, heat treatment in a tempering furnace after multi-layer printing allows the ceramic ink to fully fuse with the high-transparency glass, forming a strong bond, further improving the adhesion and stability of the pattern, effectively enhancing its weather resistance, and extending the service life of the imitation tile photovoltaic modules.

[0031] The specific embodiments of the present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0032] 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:

[0033] Figure 1 This is a flowchart illustrating the steps involved in creating a monochrome screen printing stencil in an embodiment of the present invention.

[0034] Figure 2 This is a visual representation of the monochrome screen printing stencil in an embodiment of the present invention;

[0035] Figure 3 This is an external view of the photovoltaic module in an embodiment of the present invention;

[0036] Figure 4 This is a power test diagram of the finished product sample extracted in an embodiment of the present invention;

[0037] Figure 5 This is a table of power test data and insulation withstand voltage performance test data of the finished product samples extracted in the embodiments of the present invention.

[0038] 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

[0039] 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.

[0040] 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.

[0041] 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.

[0042] like Figures 1 to 5 As shown, the manufacturing process of the top cover plate of the imitation tile photovoltaic module of the present invention includes: in a dust-free environment, using high-temperature ink or low-temperature ink, printing the imitation tile pattern onto the inner surface of high-transparency glass according to a screen printing stencil, thereby obtaining the top cover plate of the imitation tile photovoltaic module, or...

[0043] In a dust-free environment, a UV flatbed printer is used to print a tile-shaped pattern onto the inner side of a high-transparency glass to produce the top cover of the tile-shaped photovoltaic module.

[0044] The imitation tile pattern is an imitation asphalt shingle pattern or an imitation colored stone metal tile pattern; the imitation tile pattern is printed on the high-transparency glass in at least one layer;

[0045] High-transparency glass printed with imitation tile patterns using low-temperature ink printing or UV flatbed printing. After each layer of imitation tile pattern is printed, it is dried by ultraviolet irradiation.

[0046] High-transparency glass printed with imitation tile patterns using high-temperature ink is dried at room temperature after each layer of imitation tile pattern is printed. After multiple layers of imitation tile patterns are printed in sequence, the high-transparency glass with imitation tile patterns printed with high-temperature ink is heat-treated in a tempering furnace.

[0047] This invention simulates the texture and appearance of asphalt shingles / stone-coated metal tiles, ensuring that photovoltaic modules maintain a consistent style with traditional asphalt shingle roofs. This effectively solves the problem of incompatibility in appearance, enhancing the overall aesthetics and environmental adaptability of the building. The process utilizes a monochrome screen printing stencil combined with high-transparency glass, allowing for precise control of the pattern and preventing large-area continuous shading of the solar cells. This reduces the impact on photovoltaic cell power generation while achieving decorative patterns, thus improving power generation efficiency. The layering of multiple patterns better simulates the particles and textures of asphalt shingles / stone-coated metal tiles, enhancing the realism and three-dimensional granular feel of the pattern and restoring the texture and details of traditional roofing materials. Ceramic ink is used, possessing excellent high-temperature resistance, chemical corrosion resistance, and weather resistance. Furthermore, heat treatment in a tempering furnace after multi-layer printing allows the ceramic ink to fully fuse with the high-transparency glass, forming a strong bond. This further enhances the adhesion and stability of the pattern, effectively improving its weather resistance and extending the service life of the simulated asphalt shingle photovoltaic modules.

[0048] Low-temperature inks, compared to high-temperature inks, require a lower curing temperature (around 100℃). Furthermore, low-temperature inks offer vibrant colors, making them suitable for visually appealing building materials; however, their weather resistance is not as durable as that of high-temperature inks.

[0049] UV flatbed printing, compared to screen printing, can produce more detailed patterns. For mass production, multiple UV printers are needed. UV printing is far less expensive than screen printing, but it can be used for small quantities because it eliminates the need for screen printing, resulting in lower production costs.

[0050] Method for printing imitation tile-shaped patterns using a UV printer:

[0051] Take photos of real tile samples (asphalt shingle samples or colored stone metal tile samples), optimize the pattern, and convert it to CMYK mode. Import the processed image into the UV printer's dedicated software, set the print size (depending on the components being made), and resolution (300dpi). To enhance the expressiveness of the pattern, you can add white ink below the color layer to make the colors more saturated.

[0052] 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.

[0053] When printing, a UV lamp should be turned on to irradiate the glass, allowing the ink to dry and fix onto the glass surface.

[0054] In one specific embodiment of this example, the inner side of the high-transparency glass refers to the side of the high-transparency glass closest to the photovoltaic cell.

[0055] In one specific embodiment of this example, the light transmittance of the high-transmittance glass is 96%-98%.

[0056] In one specific implementation of this embodiment, "in a cleanroom" means placed in a cleanroom printing room.

[0057] In one specific embodiment of this example, drying the high-transparency glass printed with a tile-shaped pattern (imitating asphalt shingle pattern or imitation colored stone metal tile pattern) using high-temperature ink in an environment at or above room temperature includes: drying at room temperature or baking at medium temperature to preliminarily solidify and shape the printed pattern color layer and prevent overlapping between adjacent color layers.

[0058] In one specific implementation of this embodiment, the ambient temperature environment refers to the room temperature environment, which is usually 15℃-30℃.

[0059] In one specific embodiment of this example, drying in a medium-temperature environment refers to drying for 20-40 minutes at a temperature of 150-250°C in a drying oven.

[0060] Preferably, a medium-temperature environment refers to drying continuously for 30 minutes in a drying oven with an internal temperature set to 200°C.

[0061] It is understandable that the ink cures and sets faster at higher temperatures (200℃) than at room temperature (15-30℃).

[0062] Under normal temperature conditions, the curing and setting time of ink is affected by the actual temperature and humidity. Therefore, no specific time limit is set. Instead, the curing and setting time is determined by observation and testing.

[0063] Please see the appendix Figure 1 In one specific embodiment of this example, the fabrication of the screen printing stencil includes:

[0064] S1. Collect the original display image of the tile-shaped sample (asphalt shingle sample or colored stone metal tile sample) under natural light conditions;

[0065] S2. Desaturate the acquired raw display image and convert it into a bitmap structure;

[0066] S3. Extract the morphological information of the particle region in the lattice structure, and reconstruct the particle region into a dot pattern.

[0067] 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.

[0068] In one specific embodiment of this example, step S1 specifically includes: selecting a typical tile sample (asphalt shingle sample or colored stone metal tile sample), and under natural lighting conditions, acquiring a roof image (original display image) using a high-resolution photographic device to ensure that the texture and particle features of the asphalt shingle / colored stone metal tile are clearly visible in the acquired roof image.

[0069] 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, etc.), performing desaturation grayscale processing, retaining only black and white grayscale information, strengthening the contrast relationship between light and dark of the tile particles, and converting the image into a dot matrix structure.

[0070] 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.

[0071] 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.

[0072] Specifically, because photovoltaic cells are black and blue, other colors are printed on the glass surface, and patterns are formed by superimposing them with the black and blue. The black areas visible to the naked eye, i.e., the shadow areas, are not processed and are displayed using the color of the photovoltaic cell itself. For example, grayish-white areas are processed by adding dots to represent the bright areas.

[0073] In one specific embodiment of this invention, the imitation asphalt shingle photovoltaic modules / imitation colored stone metal tile photovoltaic modules are stacked one on top of another, which actually creates shadows and a sense of thickness. Therefore, during image processing, the shadows at the overlapping areas of these tiles are also represented, using dark gray or black to restore this "three-dimensionality," making the pattern printed on the glass look more realistic and spatial.

[0074] More specifically, step S2, which involves desaturating the acquired original display image and converting it into a dot matrix structure, includes:

[0075] Image grayscale conversion converts the acquired original display image (removing color information and retaining only the brightness and darkness) into a grayscale image.

[0076] 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 value (0 to 255) for each grid area;

[0077] 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.

[0078] The generated dot matrix structure results in a pattern composed of dots of different sizes, with each dot relatively independent and evenly distributed.

[0079] 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.

[0080] More specifically, including:

[0081] Select the granular region. After completing grayscale conversion and contrast adjustment, extract the areas in the image where the grayscale value is in the middle range. These areas are the granular textured parts of the asphalt shingles / colored stone metal tiles.

[0082] Image denoising and morphology optimization: using the "blur" function to remove some meaningless high-frequency noise while preserving the overall outline of the particles;

[0083] Dot-matrix processing (dot matrix reconstruction) converts the grayscale of the granular region into a dot matrix format using software.

[0084] In one specific implementation of this embodiment, the "morphological information of the granular region" refers to the detailed features such as the distribution, outline, thickness, and orientation of the granular region in the asphalt shingle image / colored stone metal tile image.

[0085] 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;

[0086] The 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.

[0087] In this application, the above operations help to identify and extract the texture and particle morphology of the asphalt shingle 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.

[0088] More specifically, the need for multiple stencils depends on the actual color composition of the asphalt shingles / colored metal sheets. If it's black or gray, no layering is needed; one stencil is sufficient. If it's colored, layering is required, and multiple (two or more) stencils need to be made.

[0089] In one specific implementation of this embodiment, the method further includes the following step before step S2:

[0090] Detect the colors contained in the acquired raw display image;

[0091] 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.

[0092] 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.

[0093] For example, if you need to make red imitation asphalt shingles (asphalt shingles):

[0094] 1. Color Separation: The original image is split into two colors: one with red as the base and the other with white to highlight the parts. This step replaces the previous step of processing the image into a grayscale image, where red acts as the gray part.

[0095] 2. Dot Reconstruction: Using the method described above, a dot matrix structure suitable for screen printing is generated. The dot diameter is controlled between 0.1mm and 1.2mm, and the dots of the two colors are staggered.

[0096] In one specific embodiment of this example, the diameter of the generated dot pattern is 0.1mm-1.2mm;

[0097] 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.

[0098] In bright areas, the density of points is low, and the distance between adjacent points is large; in dark areas, the density of points is high, and the distance between adjacent points is small.

[0099] 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.

[0100] In one specific embodiment of this example, the mesh size of the monochrome screen printing stencil is 200-350 meshes / inch, using polyester mesh with a mesh tension of 22-25N to ensure printing accuracy and print count.

[0101] The screen printing pattern is made using positive film exposure and exposed using a UV exposure machine to ensure clear edges of the pattern.

[0102] Please refer to the appendix for the appearance of the monochrome screen printing stencil. Figure 2 .

[0103] 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.

[0104] In one specific embodiment of this example, before printing the imitation tile pattern onto the high-transparency glass, the entire high-transparency glass or at least the outer surface of the high-transparency glass undergoes an acid pickling anti-reflection treatment.

[0105] 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.

[0106] In this invention, the glass surface undergoes acid washing, which effectively reduces surface reflection. Untreated glass surfaces have strong reflections, and when viewed at an angle, the bright reflective patterns can cause them to disappear or become unclear. The improved acid washing and polishing processes ensure high light transmittance while controlling the reflection angle, reducing glass reflection and ensuring that the photovoltaic modules present a perfect visual effect from various angles. This achieves the goal of meeting the requirements of high light transmittance and improved power generation efficiency while also conforming to architectural aesthetics and anti-glare requirements, thus reducing urban light pollution.

[0107] 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.

[0108] Scraper angle: 60°-75°; Scraper hardness: 75-80A.

[0109] In one specific embodiment of this example, the imitation tile pattern (imitation asphalt shingle pattern or imitation colored stone metal tile pattern) is printed on the high-transparency glass in 1-3 layers; it can be understood that the number of monochrome screen printing stencils required corresponds to the number of printing layers.

[0110] In one specific embodiment of this example, when it is necessary to use multi-layer monochrome screen printing stencils to print imitation tile patterns (imitation asphalt shingle patterns or imitation colored stone metal tile 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.

[0111] In one specific embodiment of this example, the ceramic ink includes ceramic inks in colors such as white, gray, brown, and green.

[0112] In this invention, by applying multiple layers of ceramic inks in various colors, it is easier to construct more realistic three-dimensional textures according to actual designs, thereby improving the aesthetics of photovoltaic tiles and their compatibility with the surrounding environment.

[0113] In one specific embodiment of this example, the thickness of the single-layer printed ceramic ink is 5-25 μm.

[0114] In one specific embodiment of this invention, high-transparency glass printed with a tile-like pattern (imitating asphalt shingle pattern or imitation colored stone metal tile pattern) using high-temperature ink is heat-treated 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.

[0115] 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.

[0116] The present invention also provides a roof-type photovoltaic module with a roof cover manufactured using the above-mentioned manufacturing process for the roof cover of a roof-type photovoltaic module;

[0117] The tile-shaped photovoltaic module also includes:

[0118] A photovoltaic cell, wherein the photovoltaic cell is disposed on the inside of the high-transparency glass near the top cover plate;

[0119] A first adhesive film connects the upper cover plate to the photovoltaic cell.

[0120] A lower back plate is disposed on the side of the photovoltaic cell away from the upper cover plate;

[0121] The second adhesive film connects the lower back sheet to the photovoltaic cell.

[0122] 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.

[0123] 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.

[0124] In one specific embodiment of this example, the first adhesive film and the second adhesive film may be adhesive films of the same material or adhesive films of different materials.

[0125] The first adhesive film and the second adhesive film can be EVA / POE / EPE / PVB adhesive films, etc.

[0126] In one specific embodiment of this invention, the upper cover plate, the first adhesive film, the photovoltaic cell, the second adhesive film, and the lower back plate are hot-pressed under vacuum and high-temperature conditions using a laminator. Please refer to the appendix. Figure 3 The finished photovoltaic tiles exhibit patterns resembling real asphalt shingles / colored stone metal tiles with natural colors and three-dimensional textures, and the overall power generation efficiency is no less than 90% of that of bare glass modules.

[0127] 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.

[0128] In one specific implementation of this embodiment, the test results of the finished product sample are as follows:

[0129] Light transmittance test: Light transmittance is above 85%;

[0130] Power generation performance test: Under simulated sunlight, the Pmax reduction was controlled within 5%;

[0131] Adhesion test: The ink passed the adhesion test and did not peel off;

[0132] Weather resistance test: No fading after 1000 hours of UV aging test, and no cracks after 100 cycles of hot and cold shock test.

[0133] 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 5This refers to the power test data and insulation withstand voltage test data of the sample.

[0134] This patent achieves a unified appearance and performance for tile-shaped photovoltaic modules through the combination of pattern structure design and high-temperature screen printing technology. The pattern visually replicates the texture of asphalt shingles / colored stone metal tiles, exhibiting excellent three-dimensional layering. Functionally, the dotted design and ink control effectively manage the shading area, ensuring a light transmittance of over 85% and maintaining high power generation capacity for 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.

[0135] 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.

[0136] 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 the top cover plate of a tile-shaped photovoltaic module, wherein the tile-shaped photovoltaic module includes a tile-shaped photovoltaic module imitating asphalt shingles and a tile-shaped photovoltaic module imitating colored stone metal tiles, characterized in that, include: In a dust-free environment, using high-temperature or low-temperature inks, a tile-shaped pattern is printed onto the inner surface of high-transparency glass according to a screen printing stencil to obtain the top cover plate of the tile-shaped photovoltaic module. In a dust-free environment, a UV flatbed printer is used to print a tile-shaped pattern onto the inner side of a high-transparency glass to produce the top cover of the tile-shaped photovoltaic module. The imitation tile pattern is an imitation asphalt shingle pattern or an imitation colored stone metal tile pattern; the imitation tile pattern is printed on the high-transparency glass in at least one layer; High-transparency glass printed with imitation tile patterns using low-temperature ink printing or UV flatbed printing; each layer of imitation tile pattern is dried by ultraviolet irradiation after printing. High-transparency glass printed with imitation tile patterns using high-temperature ink is dried at room temperature after each layer of imitation tile pattern is printed. After multiple layers of imitation tile patterns are printed in sequence, the high-transparency glass with imitation tile patterns printed with high-temperature ink is heat-treated in a tempering furnace. The production of the screen printing stencil includes: S1. Acquire the original display image of the tile-shaped sample under natural light conditions; the tile-shaped sample is an asphalt shingle sample or a colored stone metal tile sample; S2. Desaturate the acquired raw display image and convert it into a bitmap 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. Before the imitation tile pattern is printed on the high-transparency glass, the entire high-transparency glass or at least the outer surface of the high-transparency glass is subjected to acid washing and anti-reflection treatment.

2. The manufacturing process of the top cover plate of the imitation tile-shaped photovoltaic module according to claim 1, characterized in that, The generated dot pattern has a dot diameter of 0.1mm-1.2mm.

3. The manufacturing process of the top cover plate of the imitation tile-shaped photovoltaic module according to claim 1, characterized in that, The monochrome screen printing stencil has a mesh size of 200-350 meshes / inch, uses polyester mesh, and has a mesh tension of 22-25N.

4. The manufacturing process of the top cover plate of the imitation tile-shaped photovoltaic module according to claim 1, characterized in that, The imitation tile pattern is printed on the high-transparency glass in 1-3 layers; the number of monochrome screen printing stencils required corresponds to the number of printing layers.

5. The manufacturing process of the top cover plate of the imitation tile-shaped photovoltaic module according to claim 1, characterized in that, When multi-layer monochrome screen printing stencils are used to print the tile-shaped 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.

6. The manufacturing process of the top cover plate of the imitation tile-shaped photovoltaic module according to claim 1, characterized in that, High-transparency glass printed with imitation tile patterns using high-temperature ink is heat-treated in a tempering furnace at a tempering temperature of 650-760℃.

7. A type of photovoltaic module with a tile-like design, characterized in that, The upper cover plate is manufactured using the manufacturing process of the upper cover plate of the imitation tile photovoltaic module according to any one of claims 1-6, and the imitation tile photovoltaic module further includes: A photovoltaic cell, wherein the photovoltaic cell is disposed on the inside of the high-transparency glass near the top cover plate; A first adhesive film connects the upper cover plate to the photovoltaic cell. A lower back plate is disposed on the side of the photovoltaic cell away from the upper cover plate; The second adhesive film connects the lower back sheet to the photovoltaic cell.

8. A photovoltaic module with a tile-like design according to claim 7, characterized in that, The first adhesive film completely covers the tile-shaped pattern printed on the top cover plate.

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