Curved surface photovoltaic module and laminating method thereof

Abstract

The embodiment of the invention provides a curved-surface photovoltaic module and a laminating method thereof. The method comprises the following steps: cutting plate glass to a preset size, heating to soften the plate glass into a viscoplastic state, placing the plate glass in a forming mold with a preset curvature for compression molding, and then rapidly cooling to obtain a tempered curved-surface glass panel blank; the panel blank is subjected to secondary heating for annealing; carrying out quality inspection on linear edge curvature, bevel die marks, arched outlines and light transmittance on the molded panel; respectively cleaning the surfaces of the curved glass panel, the flexible solar cell panel and the curved back plate; an EVA bonding layer is laid on the curved-surface back plate and is trimmed, and the flexible solar cell panel, the EVA bonding layer and the curved-surface glass panel which are arranged in series are sequentially stacked and are cut and aligned layer by layer; and placing the laminated prefabricated body in a closed environment for high-temperature vacuumizing, and realizing dense compounding of each layer by using atmospheric pressure to prepare the curved-surface double-glass photovoltaic module. The bubble probability of the curved photovoltaic module is reduced, and the integrity of the formed module is ensured.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module manufacturing technology, specifically to a curved photovoltaic module and its lamination method. Background Technology

[0002] Curved photovoltaic modules are designed primarily to optimize sunlight absorption and rainwater drainage, thereby improving energy efficiency. These modules typically feature a unique curved shape to better fit building roofs and other mounting surfaces. The curved design not only increases the surface area of ​​the photovoltaic panel, capturing more sunlight, but also reduces rainwater retention, preventing performance degradation caused by water accumulation on the module surface.

[0003] Lamination is a crucial step in the manufacturing of curved photovoltaic modules. This process uses heat and pressure to tightly bond multiple layers of materials together to form a single unit. In the manufacture of curved photovoltaic modules, lamination is primarily used to combine solar cells, adhesive materials, and curved glass.

[0004] Since most photovoltaic modules are manufactured by bonding, they are exposed to the outdoors for extended periods during daily use. Prolonged exposure to sunlight and high temperatures can easily cause delamination of the photovoltaic modules. This not only affects the light transmission and energy absorption efficiency of the photovoltaic modules, but can also damage them, rendering them unusable. Therefore, a safe and stable photovoltaic module is needed. Summary of the Invention

[0005] The present invention aims to at least solve one of the technical problems existing in the prior art, and provides a curved photovoltaic module and its lamination method.

[0006] In a first aspect, embodiments of the present invention provide a lamination method for curved photovoltaic modules, the method comprising:

[0007] Flat glass is cut to a predetermined size, heated to a first preset temperature to soften it into a viscoplastic state, placed in a molding mold with a preset curvature and pressed into shape, and then rapidly cooled to obtain a tempered curved glass panel blank.

[0008] The panel blank is annealed by heating it to a second preset temperature to eliminate internal stress and enhance structural stability.

[0009] The quality inspection of the molded panel includes straight edge curvature, corner mold marks, arched contour, and light transmittance.

[0010] Clean the surfaces of the curved glass panel, flexible solar panel, and curved back panel separately;

[0011] An EVA adhesive layer is laid on the curved back panel and the edges are trimmed. Flexible solar panels, EVA adhesive layer and curved glass panel are stacked in series and aligned layer by layer.

[0012] By placing the multilayer prefabricated body in a sealed environment and evacuating it at high temperature, atmospheric pressure is used to achieve dense composite of each layer, thus producing a curved double-glass photovoltaic module.

[0013] In some possible embodiments, the first preset temperature range is 650°C to 680°C, and the second preset temperature range is 540°C to 560°C.

[0014] In some possible embodiments, the curved back panel has the same curvature on both sides as the curved glass panel.

[0015] In some possible embodiments, the curved glass panel is tempered glass, and the undulation range from the crest to the trough of the curved glass panel is 10mm to 20mm.

[0016] In some possible embodiments, the light transmittance of the glass is required to be set to be no less than 90%.

[0017] In some possible embodiments, cleaning the surfaces of the curved glass panel, the flexible solar panel, and the curved backsheet, respectively, includes:

[0018] The components are immersed in high-purity deionized water to remove residual dust and ionic impurities from the surfaces of the curved glass panel, flexible solar panel, and curved back panel. The immersed components are then dried in a cleanroom to remove moisture.

[0019] In some possible embodiments, the laminated prefabricated body is placed in a closed environment under high-temperature vacuum with the following parameter configurations:

[0020] The vacuum temperature range is 120℃~150℃, the vacuum pressure range is -0.1MPa~0.00MPa, and the vacuum holding time range is 280s~320s.

[0021] In some possible embodiments, the EVA adhesive layer comprises the following parts by weight

[0022] Raw materials:

[0023] 100 parts EVA granules, 0.7-1.1 parts plasticizer, 1-3 parts crosslinking agent, 0.2-0.6 parts tackifier and 0.2-0.6 parts antioxidant.

[0024] In some possible embodiments, the plasticizer is hydrogenated fatty acid triglyceride, the co-crosslinking agent is triallyl isocyanurate, the tackifier is γ-aminopropyltriethoxysilane, and the antioxidant is phosphorous acid.

[0025] Secondly, embodiments of the present invention provide a curved photovoltaic module, the curved photovoltaic module comprising a curved glass panel, a flexible solar panel and a curved back sheet arranged sequentially, wherein an EVA adhesive layer is provided between the curved glass panel and the curved back sheet and the flexible solar panel, and a locking groove is provided at the edge of the curved back sheet layer; wherein the curved photovoltaic module is prepared by the lamination method described above.

[0026] The curved photovoltaic module and its lamination method of this invention first prepare a curved glass panel and a curved back sheet, and then use the curved surface to shape a flexible solar panel. A one-step vacuum heating lamination method is adopted, in which the added EVA adhesive layer is melted and discharged from the chamber and the gas volatilized from the module by high temperature vacuuming, so that the EVA crosslinks and solidifies. This not only reduces the probability of bubbles in the prepared curved photovoltaic module, but also ensures the integrity of the prepared module and avoids delamination and damage during subsequent use, thereby effectively ensuring the performance and service life of the photovoltaic module. Attached Figure Description

[0027] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the structure of a curved photovoltaic module according to an embodiment of the present invention.

[0029] The attached figures are labeled as follows:

[0030] 10 Curved glass panel, 20 Flexible solar panel, 30 Curved backsheet, 31 Fixing groove, 40 EVA adhesive layer. Detailed Implementation

[0031] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0032] Unless otherwise specifically stated, the technical or scientific terms used in the embodiments of this invention should be understood in their ordinary sense by those skilled in the art to which this invention pertains. The terms "comprising" or "including," as used in the embodiments of this invention, do not limit the shapes, numbers, steps, actions, operations, components, elements, and / or groups thereof mentioned, nor do they exclude the appearance or addition of one or more other different shapes, numbers, steps, actions, operations, components, elements, and / or groups thereof, or the addition of these. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number and order of the indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the embodiments of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0033] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale, and techniques, methods, and apparatus known to those skilled in the art may not be discussed in detail; however, where appropriate, the illustrated techniques, methods, and apparatus should be considered part of the specification. In all the examples shown and discussed herein, any other specific example may have different values. It should be noted that similar symbols and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0034] In the description of the embodiments of the present invention, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In the embodiments of the present invention, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in the embodiments of the present invention, as well as the features of different embodiments or examples.

[0035] Hereinafter, exemplary embodiments according to the present invention will be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments of the present invention. It should be understood that the present invention is not limited to the exemplary embodiments described herein.

[0036] Example 1:

[0037] like Figure 1 As shown, this embodiment of the invention provides a lamination method for a curved photovoltaic module, including a curved glass panel 10, a flexible solar panel 20, and a curved back sheet 30 arranged from top to bottom. An EVA adhesive layer 40 is provided between the curved glass panel 10, the curved back sheet 30, and the flexible solar panel 20. A locking groove 31 is provided at the bottom edge of the curved back sheet 30 for installing an external sealing strip / frame to ensure overall installation stability. The double-sided curvature of the curved back sheet 30 is the same as that of the curved glass panel 10. The curved glass panel 10 is made of tempered glass, and the undulation range from the crest to the trough of the curved glass panel 10 is set to 20 mm. The specific preparation steps are as follows:

[0038] Step S1: Preparation of curved panel;

[0039] S1.1 Hot bending tempering: Cut the flat glass to the required size. The good flat glass is heated evenly to a temperature of 660℃. At this temperature, the glass becomes a viscoplastic state. The softened glass flat plate is placed on a mold with a set bending inner cavity for the curved glass panel 10. After pressing, it is quickly cooled to form a tempered curved glass panel blank.

[0040] S1.2 Hot bending annealing: The preform of the glass after gravity deformation in step S1.1 is reheated to a temperature of 550°C. At this temperature, the glass is stress-free, increasing the strength and stability of the glass.

[0041] S1.3 Panel Quality Inspection: Inspect the appearance of the panel formed in step S1.2. The inspection items include, but are not limited to, the bending of the straight edges of the panel glass, mold marks at the corners, arched contours, and the light transmittance of the glass. The light transmittance of the glass is required to be no less than 90%.

[0042] S2. Component cleaning: The curved glass panel 10, flexible solar panel 20 and curved back panel 30 are cleaned in sequence by immersing them in high-purity deionized water to remove residual dust and ionic impurities on the surface. After immersion, the components are dried in a clean room to remove moisture and surface impurities.

[0043] S3. Laying: Cover the curved back plate 30 with an EVA adhesive layer 40, and cut and align the EVA adhesive layer 40 that extends beyond the edge of the curved back plate 30. Then, connect the flexible solar panels 20 one by one in series and arrange them evenly on the top of the cut EVA adhesive layer 40. Then, cover the EVA adhesive layer 40 and the curved glass panel 10 in sequence, and cut and align the EVA adhesive layer 40 at the bottom of the curved glass panel 10 to obtain the prefabricated sample.

[0044] EVA adhesive layer 40 comprises the following raw materials in parts by weight: 100 parts EVA granules, 0.7-1.1 parts hydrogenated fatty acid triglycerides, 1-3 parts triallyl isocyanurate, 0.2-0.6 parts γ-aminopropyltriethoxysilane, and 0.2-0.6 parts phosphorous acid. It is produced by a casting process, and the process flow is as follows: mixing – extrusion – casting – thickness measurement – ​​embossing – shaping – edge trimming – winding.

[0045] S4. Vacuuming: The pre-made sample obtained in step S3 is placed in a closed space for high-temperature vacuuming. The vacuum conditions are set to 120°C, the vacuum parameters are set to 0.00MPa, and the vacuuming and pressure holding time is 300s. By using the external atmospheric pressure, the materials of each layer are compacted, and the curved double-glass photovoltaic module can be obtained.

[0046] Specifically in this embodiment: the EVA adhesive layer 40 comprises the following raw materials in parts by weight: 100 parts of EVA particles, 0.7 parts of hydrogenated fatty acid triglycerides, 3 parts of triallyl isocyanurate, 0.2 parts of γ-aminopropyltriethoxysilane, and 0.2 parts of phosphorous acid.

[0047] Example 2:

[0048] This invention provides a lamination method for a curved photovoltaic module, comprising a curved glass panel 10, a flexible solar panel 20, and a curved backsheet 30 arranged from top to bottom. An EVA adhesive layer 40 is provided between the curved glass panel 10, the curved backsheet 30, and the flexible solar panel 20. A locking groove 31 is provided at the bottom edge of the curved backsheet 30 for installing an external sealing strip / frame to ensure overall installation stability. The double-sided curvature of the curved backsheet 30 is the same as that of the curved glass panel 10. The curved glass panel 10 is made of tempered glass, and the undulation range from the crest to the trough of the curved glass panel 10 is set to 15 mm. The specific preparation steps are as follows:

[0049] Step S1: Preparation of curved panel;

[0050] S1.1 Hot bending tempering: Cut the flat glass to the required size. The good flat glass is heated evenly to a temperature of 650℃. At this temperature, the glass becomes a viscoplastic state. The softened glass flat plate is placed on a mold with a set bending inner cavity for the curved glass panel 10. After pressing, it is quickly cooled to form a tempered curved glass panel blank.

[0051] S1.2 Hot bending annealing: The preform of the glass after gravity deformation in step S1.1 is reheated to a temperature of 550°C. At this temperature, the glass is stress-free, increasing the strength and stability of the glass.

[0052] S1.3 Panel Quality Inspection: Inspect the appearance of the panel formed in step S1.2. The inspection items include, but are not limited to, the bending of the straight edges of the panel glass, mold marks at the corners, arched contours, and the light transmittance of the glass. The light transmittance of the glass is required to be no less than 90%.

[0053] S2. Component cleaning: The curved glass panel 10, flexible solar panel 20 and curved back panel 30 are cleaned in sequence by immersing them in high-purity deionized water to remove residual dust and ionic impurities on the surface. After immersion, the components are dried in a clean room to remove moisture and surface impurities.

[0054] S3. Laying: Cover the curved back plate 30 with an EVA adhesive layer 40, and cut and align the EVA adhesive layer 40 that extends beyond the edge of the curved back plate 30. Then, connect the flexible solar panels 20 one by one in series and arrange them evenly on the top of the cut EVA adhesive layer 40. Then, cover the EVA adhesive layer 40 and the curved glass panel 10 in sequence, and cut and align the EVA adhesive layer 40 at the bottom of the curved glass panel 10 to obtain the prefabricated sample.

[0055] EVA adhesive layer 40 comprises the following raw materials in parts by weight: 100 parts EVA granules, 0.7-1.1 parts hydrogenated fatty acid triglycerides, 1-3 parts triallyl isocyanurate, 0.2-0.6 parts γ-aminopropyltriethoxysilane, and 0.2-0.6 parts phosphorous acid. It is produced by a casting process, and the process flow is as follows: mixing – extrusion – casting – thickness measurement – ​​embossing – shaping – edge trimming – winding.

[0056] S4. Vacuuming: The pre-made sample obtained in step S3 is placed in a closed space for high-temperature vacuuming. The vacuum conditions are set to 120°C, the vacuum parameters are set to 0.00MPa, and the vacuuming and pressure holding time is 300s. By using the external atmospheric pressure, the materials of each layer are compacted, and the curved double-glass photovoltaic module can be obtained.

[0057] Specifically in this embodiment: the EVA adhesive layer 40 comprises the following raw materials in parts by weight: 100 parts of EVA particles, 0.9 parts of hydrogenated fatty acid triglycerides, 2 parts of triallyl isocyanurate, 0.4 parts of γ-aminopropyltriethoxysilane, and 0.4 parts of phosphorous acid.

[0058] Example 3:

[0059] This invention provides a lamination method for a curved photovoltaic module, comprising a curved glass panel 10, a flexible solar panel 20, and a curved backsheet 30 arranged from top to bottom. An EVA adhesive layer 40 is provided between the curved glass panel 10, the curved backsheet 30, and the flexible solar panel 20. A locking groove 31 is provided at the bottom edge of the curved backsheet 30 for installing an external sealing strip / frame to ensure overall installation stability. The double-sided curvature of the curved backsheet 30 is the same as that of the curved glass panel 10. The curved glass panel 10 is made of tempered glass, and the undulation range from the crest to the trough of the curved glass panel 10 is set to 10 mm. The specific preparation steps are as follows:

[0060] Step S1: Preparation of curved panel;

[0061] S1.1 Hot bending tempering: Cut the flat glass to the required size. The good flat glass is heated evenly to a temperature of 650℃. At this temperature, the glass becomes a viscoplastic state. The softened glass flat plate is placed on a mold with a set bending inner cavity for the curved glass panel 10. After pressing, it is quickly cooled to form a tempered curved glass panel blank.

[0062] S1.2 Hot bending annealing: The preform of the glass after gravity deformation in step S1.1 is reheated to a temperature of 550°C. At this temperature, the glass is stress-free, increasing the strength and stability of the glass.

[0063] S1.3 Panel Quality Inspection: Inspect the appearance of the panel formed in step S1.2. The inspection items include, but are not limited to, the bending of the straight edges of the panel glass, mold marks at the corners, arched contours, and the light transmittance of the glass. The light transmittance of the glass is required to be no less than 90%.

[0064] S2. Component cleaning: The curved glass panel 10, flexible solar panel 20 and curved back panel 30 are cleaned in sequence by immersing them in high-purity deionized water to remove residual dust and ionic impurities on the surface. After immersion, the components are dried in a clean room to remove moisture and surface impurities.

[0065] S3. Laying: Cover the curved back plate 30 with an EVA adhesive layer 40, and cut and align the EVA adhesive layer 40 that extends beyond the edge of the curved back plate 30. Then, connect the flexible solar panels 20 one by one in series and arrange them evenly on the top of the cut EVA adhesive layer 40. Then, cover the EVA adhesive layer 40 and the curved glass panel 10 in sequence, and cut and align the EVA adhesive layer 40 at the bottom of the curved glass panel 10 to obtain the prefabricated sample.

[0066] EVA adhesive layer 40 comprises the following raw materials in parts by weight: 100 parts EVA granules, 0.7-1.1 parts hydrogenated fatty acid triglycerides, 1-3 parts triallyl isocyanurate, 0.2-0.6 parts γ-aminopropyltriethoxysilane, and 0.2-0.6 parts phosphorous acid. It is produced by a casting process, and the process flow is as follows: mixing – extrusion – casting – thickness measurement – ​​embossing – shaping – edge trimming – winding.

[0067] S4. Vacuuming: The pre-made sample obtained in step S3 is placed in a closed space for high-temperature vacuuming. The vacuum conditions are set to 150°C, the vacuum parameters are set to 0.00MPa, and the vacuuming and pressure holding time is 300s. By using the external atmospheric pressure, the materials of each layer are compacted, and the curved double-glass photovoltaic module can be obtained.

[0068] Specifically in this embodiment: the EVA adhesive layer 40 comprises the following raw materials in parts by weight: 100 parts of EVA particles, 1.1 parts of hydrogenated fatty acid triglycerides, 3 parts of triallyl isocyanurate, 0.6 parts of γ-aminopropyltriethoxysilane, and 0.6 parts of phosphorous acid.

[0069] Example 4:

[0070] The curved photovoltaic modules prepared in Examples 1-3 above were subjected to performance testing, and the following data were obtained:

[0071]

[0072]

[0073] As shown in the table above, the raw material ratio in Example 2 is appropriate. The peel strength of the curved photovoltaic module prepared by this method reaches more than 9 N / cm, the crosslinking degree reaches more than 85%, and the probability of air bubbles in the prepared curved photovoltaic module is less than 0.15%, thereby ensuring the quality of the prepared curved photovoltaic module and providing a good guarantee for its protection against the influence of high temperature and sunlight during subsequent use.

[0074] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of the present invention, and the present invention is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also considered to be within the scope of protection of the present invention.

Claims

1. A lamination method for curved photovoltaic modules, characterized in that, The method includes: Flat glass is cut to a predetermined size, heated to a first preset temperature to soften it into a viscoplastic state, placed in a molding mold with a preset curvature and pressed into shape, and then rapidly cooled to obtain a tempered curved glass panel blank. The panel blank is annealed by heating it to a second preset temperature to eliminate internal stress and enhance structural stability. The quality inspection of the molded panel includes straight edge curvature, corner mold marks, arched contour, and light transmittance. Clean the surfaces of the curved glass panel, flexible solar panel, and curved back panel separately; An EVA adhesive layer is laid on the curved back panel and the edges are trimmed. Flexible solar panels, EVA adhesive layer and curved glass panel are stacked in series and then cut and aligned layer by layer. By placing the multilayer prefabricated body in a sealed environment and evacuating it at high temperature, atmospheric pressure is used to achieve dense composite of each layer, thus producing a curved double-glass photovoltaic module.

2. The lamination method for a curved photovoltaic module according to claim 1, characterized in that, The first preset temperature range is 650℃~680℃, and the second preset temperature range is 540℃~560℃.

3. The lamination method for a curved photovoltaic module according to claim 1, characterized in that, The curved back panel has the same curvature on both sides as the curved glass panel.

4. A lamination method for a curved photovoltaic module according to any one of claims 1 to 3, characterized in that, The curved glass panel is made of tempered glass, and the undulation range from the crest to the trough of the curved glass panel is 10mm to 20mm.

5. A lamination method for a curved photovoltaic module according to any one of claims 1 to 3, characterized in that, The light transmittance of the glass is required to be no less than 90%.

6. A lamination method for a curved photovoltaic module according to any one of claims 1 to 3, characterized in that, The cleaning of the surfaces of the curved glass panel, flexible solar panel, and curved back panel respectively includes: The components are immersed in high-purity deionized water to remove residual dust and ionic impurities from the surfaces of the curved glass panel, flexible solar panel, and curved back panel. The immersed components are then dried in a cleanroom to remove moisture.

7. A lamination method for a curved photovoltaic module according to any one of claims 1 to 3, characterized in that, Under the following parameter configurations, the laminated prefabricated body is placed in a sealed environment under high temperature and vacuum: The vacuum temperature range is 120℃~150℃, the vacuum pressure range is -0.1MPa~0.00MPa, and the vacuum holding time range is 280s~320s.

8. A lamination method for a curved photovoltaic module according to any one of claims 1 to 3, characterized in that, The EVA adhesive layer comprises the following raw materials in parts by weight: 100 parts EVA granules, 0.7-1.1 parts plasticizer, 1-3 parts crosslinking agent, 0.2-0.6 parts tackifier and 0.2-0.6 parts antioxidant.

9. The lamination method for a curved photovoltaic module according to claim 8, characterized in that, The plasticizer is hydrogenated fatty acid triglyceride, the co-crosslinking agent is triallyl isocyanurate, the tackifier is γ-aminopropyltriethoxysilane, and the antioxidant is phosphorous acid.

10. A curved photovoltaic module, characterized in that, The curved photovoltaic module includes a curved glass panel, a flexible solar panel, and a curved back sheet arranged in sequence. An EVA adhesive layer is provided between the curved glass panel and the curved back sheet and the flexible solar panel. A locking groove is provided at the edge of the curved back sheet layer. The curved photovoltaic module is prepared by the lamination method according to any one of claims 1 to 9.

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