A lightweight photovoltaic module with heat insulation and noise reduction functions and its preparation method

Abstract

This invention provides a lightweight photovoltaic module with heat insulation and noise reduction functions and its preparation method, relating to the field of photovoltaic module technology. The lightweight photovoltaic module structure includes: a front panel, an encapsulation layer, photovoltaic cells, a microcavity composite layer, and a back panel; the microcavity composite layer comprises: aerogel particles, polymer foamed microspheres, and a thermosetting resin matrix; the porosity of the aerogel particles is 85%-99%, and the particle size of the polymer foamed microspheres is 3-30 μm; the polymer foamed microspheres are thermoplastic polymer microspheres selected from at least one of polymethyl methacrylate, polyacrylonitrile, and polyvinylidene chloride. This invention overcomes the shortcomings of existing lightweight photovoltaic modules that are functionally limited and cannot meet the heat and sound insulation requirements of building envelopes, providing a multifunctional lightweight photovoltaic module integrating power generation, heat insulation, and noise reduction functions, as well as its preparation method.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic module technology, specifically relating to a lightweight photovoltaic module with heat insulation and noise reduction functions and its preparation method. Background Technology

[0002] Existing lightweight photovoltaic modules mainly focus on achieving weight reduction and flexibility by using polymer materials (such as ETFE and PET) to replace glass, resulting in relatively limited functionality. When these modules are applied to building envelopes (such as roofs and exterior walls), they are often regarded as simple power generation units, neglecting the building's own physical performance requirements for thermal insulation and sound insulation.

[0003] To achieve sound insulation and heat preservation, the common practice is to add additional insulation layers such as rock wool and polystyrene boards, and sound insulation layers such as gypsum board and sound insulation felt after installing photovoltaic modules. While adding sound or heat insulation layers to the outside of the modules can achieve the effects of heat insulation and sound insulation, this separate design of the "power generation system + building function system" leads to problems such as system complexity, increased total weight, long construction period, and high cost, failing to fully realize the advantages of BIPV (Building Integrated Photovoltaics). For example, Chinese invention patent CN118317693A discloses a light-transmitting panel for buildings such as greenhouses. This light-transmitting panel includes a light-transmitting member located between the inner and outer surfaces of the panel. The light-transmitting member includes multiple light-transmitting devices (e.g., light guides) and an insulating body that at least partially surrounds the light-transmitting devices. Each light-transmitting device includes a light-receiving part, a light-emitting part, and a transmission part between the light-receiving part and the light-emitting part. The panel can be connected to a frame along its perimeter. The insulation in the light-transmitting panel contains polymer materials, which may be foam, polyurethane, rubber, expanded polystyrene, and / or silicone aerogel.

[0004] Existing lightweight wall or roof-mounted modules use polymer and fiberglass composite materials as the front and back panels, bonded together with adhesive films and cells. However, in high summer temperatures and strong radiation environments, their internal temperature still rises significantly, leading to a decrease in power generation efficiency. Although there are technical solutions such as adding metal heat sinks or forced air cooling, these solutions compromise the lightweight characteristics and aesthetic consistency of the modules, and introduce additional energy consumption and costs.

[0005] Chinese invention patent CN110931585A discloses an improved crystalline silicon photovoltaic module backsheet and its preparation method, which exhibits high reflectivity and features a simple manufacturing process and low production cost. The crystalline silicon photovoltaic module backsheet includes a high-reflectivity micro-foamed layer with micropores. The high-reflectivity micro-foamed layer is obtained by physical foaming and / or chemical foaming of high-reflectivity micro-foaming raw materials, followed by curing and shaping. The high-reflectivity micro-foaming raw materials include: 90-100 parts by weight of resin, 0.001-10 parts by weight of foaming agent, 0-30 parts by weight of inorganic filler, and 1-30 parts by weight of reflective filler; the reflective filler is selected from one or more combinations of SiO2 aerogel micropowder and metal powder.

[0006] Although adding a high-reflectivity micro-foam layer to the backsheet can improve the weather resistance of the backsheet in existing technologies, it does not solve technical problems such as heat conduction and sound insulation, that is, it does not solve the technical requirements of the component itself to have heat insulation and sound insulation and noise reduction.

[0007] Therefore, a new approach is needed to overcome the shortcomings of existing lightweight photovoltaic modules, such as their limited functionality and inability to meet the thermal and sound insulation requirements of building envelopes. Summary of the Invention

[0008] This invention addresses the problems existing in the prior art by providing a lightweight photovoltaic module with heat insulation and noise reduction functions, as well as its preparation method. The primary objective of this invention is to overcome the shortcomings of existing lightweight photovoltaic modules, which have limited functionality and cannot meet the heat and sound insulation requirements of building envelopes. It provides a multifunctional lightweight photovoltaic module integrating power generation, heat insulation, and noise reduction functions, along with its preparation method.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0010] On the one hand, the present invention provides a lightweight photovoltaic module with heat insulation and noise reduction functions. The lightweight photovoltaic module structure includes: a front panel, a first encapsulation layer, photovoltaic cells, a second encapsulation layer, a microcavity composite layer, and a back panel.

[0011] The microcavity composite layer comprises: aerogel particles, polymer foamed microspheres, and a thermosetting resin matrix; the porosity of the aerogel particles is 85%-99%, and the particle size of the polymer foamed microspheres is 3μm-30μm.

[0012] The polymer foamed microspheres are thermoplastic polymer microspheres selected from at least one of polymethyl methacrylate (PMMA), polyacrylonitrile (PAN), and polyvinylidene chloride (PVDC).

[0013] Preferably, in the microcavity composite layer, the mass ratio of aerogel particles, polymer foamed microspheres, and thermosetting resin matrix is ​​30-50:5-15:35-55.

[0014] More preferably, in the microcavity composite layer, the mass ratio of aerogel particles, polymer foamed microspheres, and thermosetting resin matrix is ​​40:10:45.

[0015] Preferably, the aerogel particles are selected from at least one of silica aerogel particles, alumina aerogel particles, titanium dioxide aerogel particles, and polyimide aerogel particles.

[0016] More preferably, the aerogel particles are nano-silica aerogels.

[0017] Preferably, the porosity of the aerogel particles is 90%-95%.

[0018] Preferably, the size of the aerogel particles is 5μm-25μm; more preferably, the size of the aerogel particles is 5μm-15μm.

[0019] Preferably, the polymer foamed microspheres are thermoplastic polymer microspheres that have not been foamed before use.

[0020] More preferably, the polymer foamed microspheres are selected from polymethyl methacrylate (PMMA).

[0021] Preferably, the particle size of the polymer foamed microspheres is 5μm-25μm.

[0022] More preferably, the particle size of the polymer foamed microspheres is 10μm-20μm.

[0023] Preferably, the thermosetting resin matrix is ​​selected from at least one of polyurethane resin, polyester resin, and hydroxyl acrylic resin.

[0024] More preferably, the polyurethane resin is a liquid polyurethane resin.

[0025] Preferably, the thickness of the microcavity composite layer is 50 μm-300 μm. More preferably, the thickness of the microcavity composite layer is 50 μm-200 μm.

[0026] Preferably, the microcavity composite layer further includes an auxiliary component; the auxiliary component includes a dispersant, an antifoaming agent, and a crosslinking agent.

[0027] More preferably, the dispersant is a conventional dispersant in the art, and is not limited to at least one of BYK-161 (BYK-161 dispersant) and EFKA™-4010 (EFKA 4010 dispersant).

[0028] More preferably, the defoamer is a conventional defoamer in the art, and is not limited to at least one of BYK-071, TEGO® Airex 900, and EFKA® 2020.

[0029] More preferably, the crosslinking agent is a conventional crosslinking agent in the art, and is not limited to HT-100 (HDI (hexamethylene diisocyanate) trimer derivative), Desmodur N75 (HDI biuret derivative), isophorone diisocyanate and its derivatives (IPDI and its derivatives).

[0030] Preferably, the weight ratio of the additive component in the microcavity composite layer to the total weight of the aerogel particles, polymer foamed microspheres and thermosetting resin matrix is ​​7-12:80-95.

[0031] More preferably, the weight ratio of the additive component in the microcavity composite layer to the total weight of the aerogel particles, polymer foamed microspheres and thermosetting resin matrix is ​​7-12:88-95.

[0032] Within the range of 7-12:80-95, the technical effect described in this invention can be achieved even within any point value or any two point values ​​in the microcavity composite layer described in the invention. For example, 7:95, 10:90, 12:88.

[0033] Preferably, the structure of the lightweight photovoltaic module, from the light incident surface to the back light surface, is as follows: front panel 1, first encapsulation layer 2, photovoltaic cell 3, second encapsulation layer 4, microcavity composite layer 5, and back panel 6.

[0034] More preferably, the structure of the lightweight photovoltaic module, from the light incident surface to the back light surface, is as follows: a transparent front panel 1, a first encapsulation layer 2, a photovoltaic cell 3, a second encapsulation layer 4, a microcavity composite layer 5, and a back panel 6; the microcavity composite layer includes: aerogel particles 5-1, polymer foamed microspheres 5-2, and a thermosetting resin matrix 5-3.

[0035] Preferably, the front panel is selected from one or more of ETFE film (ethylene-tetrafluoroethylene copolymer film), PVDF film (polyvinylidene fluoride film), and PET board (polyterephthalic acid plastic board); it can be a single layer or a multi-layer composite board; more preferably, the PET board is a transparent PET board.

[0036] Preferably, the first encapsulation layer is composed of at least one of EVA (ethylene-vinyl acetate copolymer) and POE (polyolefin elastomer).

[0037] Preferably, the photovoltaic cell is selected from crystalline silicon cells or perovskite cells.

[0038] Preferably, the second encapsulation layer is composed of at least one of EVA and POE.

[0039] Preferably, the backsheet is composed of at least one of PET-coated fluorocarbon resin, PP (polypropylene) fiberglass board, and epoxy fiberglass board. More preferably, the PET-coated fluorocarbon resin is a transparent PET-coated fluorocarbon resin.

[0040] Preferably, the thickness of the front panel is 0.02mm-0.03mm; more preferably, the thickness of the front panel is 0.025mm.

[0041] Preferably, the thickness of the first encapsulation layer or the second encapsulation layer is 0.4mm-0.6mm; more preferably, the thickness of the first encapsulation layer or the second encapsulation layer is 0.5mm.

[0042] Preferably, the photovoltaic cell is a conventional cell in the art, cut into a standard size of 182mm × 182mm.

[0043] Preferably, the thickness of the back plate is 0.3mm-0.8mm; more preferably, the thickness of the back plate is 0.3mm.

[0044] Preferably, the preparation method of the microcavity composite layer includes the following steps: mixing aerogel particles, polymer foamed microspheres and thermosetting resin matrix evenly, coating, and curing at 40℃-80℃ for 48h-96h to obtain the microcavity composite layer.

[0045] More preferably, the uniform mixing is achieved by high-speed stirring at a speed of 1000-2000 rpm. Even more preferably, the uniform mixing is achieved by high-speed stirring at a speed of 1500 rpm.

[0046] More preferably, during the process of mixing evenly, an auxiliary agent may be added.

[0047] More preferably, the preparation method of the microcavity composite layer includes the following steps: mixing aerogel particles, polymer foamed microspheres and thermosetting resin matrix evenly, coating, pre-curing, and then aging at 40℃-80℃ for 48h-96h to obtain the microcavity composite layer; the pre-curing temperature is 100℃-170℃.

[0048] More preferably, the preparation method of the microcavity composite layer includes the following steps: mixing aerogel particles, polymer foamed microspheres and thermosetting resin matrix evenly, coating, pre-curing at 150°C, and then aging at 40°C for 48 hours to obtain the microcavity composite layer.

[0049] More preferably, the initial curing is carried out in an oven.

[0050] More preferably, the coating is a wet coating applied to the backing plate, and the coating thickness is 50 μm-300 μm. More preferably, the coating thickness is 200 μm.

[0051] On the other hand, the present invention provides a method for preparing the above-mentioned lightweight photovoltaic module, comprising the steps of: stacking a front panel, a first encapsulation layer, a photovoltaic cell, a second encapsulation layer, a microcavity composite layer and a back panel in the above order; sending the stacked module into a laminator for lamination; evacuating and heating during lamination; and then cooling to obtain a lightweight photovoltaic module.

[0052] Preferably, the vacuum level is below 50 Pa.

[0053] Preferably, the heating temperature is 140℃-150℃ and the heating time is 15min-25min.

[0054] More preferably, the heating temperature is 145°C and the heating time is 20 minutes.

[0055] In this invention, the front panel, the first encapsulation layer, the photovoltaic cell, the second encapsulation layer, and the back panel are all conventional products in the art, and different components and different preparation methods do not have a significant impact on the technical effect.

[0056] In some specific embodiments of the present invention, the front plate is a conventional ETFE film, or a PVDF film, or a PET sheet.

[0057] In one specific embodiment of the present invention, both the first encapsulation layer and the second encapsulation layer are POE encapsulation films.

[0058] In one specific embodiment of the present invention, the photovoltaic cell is a P-type monocrystalline silicon cell.

[0059] In one specific embodiment of the present invention, the back sheet is PET coated with fluorocarbon resin.

[0060] Compared with the prior art, the present invention has the following beneficial effects:

[0061] 1. The lightweight photovoltaic module of the present invention introduces a microcavity composite layer, realizing the triple functions of "photovoltaic power generation", "passive heat insulation" and "wideband noise reduction"; the component can be used directly as a power generation building material, eliminating the need for subsequent additional heat insulation and sound insulation layers, simplifying the building structure and reducing the total cost and weight.

[0062] 2. In this invention, the microcavity composite layer comprises aerogel particles, polymer foamed microspheres, and a thermosetting resin matrix. The microcavity composite layer is prepared using components of specific types, particle sizes, and porosities. Due to its numerous micro- and nano-scale closed pores and the extremely low thermal conductivity of the aerogel itself, it constitutes a highly efficient thermal barrier, effectively blocking the transfer of outdoor heat to the interior and reducing the building's air conditioning cooling load. It also reflects infrared radiation not absorbed by the battery, reducing heat generation at the source, while simultaneously preventing the heat generated by the battery from being conducted to the back of the component, thereby effectively reducing the battery's operating temperature and improving power generation efficiency and long-term reliability.

[0063] 3. By controlling the size, composition, composition distribution, and acoustic impedance of the microcavity composite layer, this invention can significantly absorb and dissipate noise in specific frequency bands (especially mid-to-high frequencies), effectively improving the airborne sound insulation performance of building envelopes.

[0064] 4. The aerogel particles and polymer foamed microspheres used in this invention are both ultralight materials, and the resulting microcavity composite layer has a low density. While giving the component additional functions, the increase in the overall weight of the component is negligible, thus retaining the core advantages of lightweight photovoltaic modules.

[0065] 5. The lightweight photovoltaic module preparation method of this invention can be integrated with existing mature photovoltaic module lamination processes without adding complex or expensive production equipment. By adjusting the laminar material sequence and improving lamination process parameters, lightweight photovoltaic modules with significantly improved heat insulation and noise reduction effects can be prepared. This invention has the potential for large-scale industrial application. The thickness of the microcavity composite layer of this invention is 50μm-200μm, the thermal conductivity is less than 0.05W / (m·K), and the weighted sound insulation of airborne sound in the frequency range of 500Hz-4000Hz is improved by no less than 5dB. Attached Figure Description

[0066] Figure 1 This is a structural diagram of the lightweight photovoltaic module of the present invention.

[0067] Among them, 1. front panel; 2. first encapsulation layer; 3. photovoltaic cell; 4. second encapsulation layer; 5. microcavity composite layer; 5-1. aerogel particles; 5-2. polymer foamed microspheres; 5-3. thermosetting resin matrix; 6. back panel. Detailed Implementation

[0068] The following non-limiting embodiments are intended to enable those skilled in the art to gain a more comprehensive understanding of the present invention, but do not limit the invention in any way. The following content is merely an exemplary description of the scope of protection claimed by the present invention, and those skilled in the art can make various changes and modifications to the present invention based on the disclosed content, and such changes should also fall within the scope of protection claimed by the present invention.

[0069] When numerical ranges are given in the embodiments, it should be understood that, unless otherwise stated in the invention, both endpoints of each numerical range and any value between the two endpoints may be selected. Unless otherwise defined, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0070] The present invention will be further described below by way of specific embodiments. Unless otherwise specified, all chemical reagents used in the embodiments of the present invention are obtained through conventional commercial means.

[0071] In the specific implementation of this invention, the sources of the main raw materials used are shown in Table 1. The sources of these raw materials are merely exemplary, and products from different manufacturers do not have a significant impact on the effect.

[0072] Table 1

[0073]

[0074] Example 1

[0075] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0076] Transparent front panel 1: ETFE film with a thickness of 0.025mm is selected.

[0077] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0078] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0079] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0080] Microcavity composite layer 5:

[0081] The preparation method is as follows: 40 parts of nano-silica aerogel powder (5-1, Cabot Enova® aerogel powder, particle size 5μm, porosity 95%), 10 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 10μm, PMMA), 45 parts of liquid polyurethane resin (5-3), 5 parts of crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500rpm to form a paste; the paste is coated onto a backing plate, the wet film thickness is controlled to be about 200μm, and it is initially cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0082] Back panel 6: PET coated fluorocarbon resin board, 0.3mm thick.

[0083] The preparation method of lightweight photovoltaic modules is as follows:

[0084] The transparent front panel 1, the first encapsulation layer 2, the photovoltaic cell 3, the second encapsulation layer 4, the microcavity composite layer 5, and the backsheet 6 are stacked in the above order. The stacked module is then fed into a laminator, and a vacuum is drawn to a level below 50 Pa. It is then heated to 145°C and held at this temperature for 20 minutes. During this process, the POE encapsulation film melts and flows, filling all gaps and completing the encapsulation of the cells. Simultaneously, the polyurethane resin undergoes cross-linking and curing, and the thermoplastic polymer microspheres expand upon heating, forming numerous closed micro-nano pores within the cured polyurethane resin matrix. These pores, together with the aerogel particles, ultimately form a robust and microcavity-filled composite layer. After lamination, the module is cooled to obtain a lightweight photovoltaic module.

[0085] Example 2

[0086] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0087] Transparent front panel 1: PVDF film with a thickness of 0.025mm is selected.

[0088] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0089] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0090] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0091] Microcavity composite layer 5:

[0092] The preparation method is as follows: 30 parts of nano-silica aerogel powder (5-1, Cabot Enova® aerogel powder, particle size 15μm, porosity 95%), 5 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 20μm, PMMA), 55 parts of liquid polyurethane resin (5-3), 8 parts of crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500rpm to form a paste; the paste is coated onto a backing plate, the wet film thickness is controlled to be about 50μm, and it is initially cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0093] Back panel 6: PET coated fluorocarbon resin board, 0.3mm thick.

[0094] The preparation method of the lightweight photovoltaic module is the same as in Example 1.

[0095] Example 3

[0096] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0097] Transparent front panel 1: PET sheet with a thickness of 0.025mm is selected.

[0098] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0099] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0100] Second encapsulation layer 4: Uses an EVA encapsulation film with a thickness of 0.5mm.

[0101] Microcavity composite layer 5:

[0102] The preparation method is as follows: 50 parts of nano-silica aerogel powder (5-1, Cabot Enova® aerogel powder, particle size 5μm, porosity 90%), 10 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 20μm, PMMA), 35 parts of liquid polyurethane resin (5-3), 5 parts of crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500rpm to form a paste; the paste is coated onto a backing plate, the wet film thickness is controlled to be about 200μm, and it is initially cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0103] Back panel 6: PET coated fluorocarbon resin board, 0.3mm thick.

[0104] The preparation method of the lightweight photovoltaic module is the same as in Example 1.

[0105] Example 4

[0106] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0107] Transparent front panel 1: PVDF film with a thickness of 0.025mm is selected.

[0108] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0109] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0110] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0111] Microcavity composite layer 5:

[0112] The preparation method is as follows: 30 parts of nano-silica aerogel powder (5-1, alumina aerogel, particle size 25μm, porosity 95%), 5 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 20μm, PMMA), 53 parts of liquid polyurethane resin (5-3), 8 parts of crosslinking agent (HDI biuret, Desmodur N3390), 2 parts of dispersant (BYK-161) and 2 parts of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500rpm to form a paste; the paste is coated onto a backing plate, the wet film thickness is controlled to be about 50μm, and it is initially cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0113] Back panel 6: PET coated fluorocarbon resin board, 0.3mm thick.

[0114] The preparation method of the lightweight photovoltaic module is the same as in Example 1.

[0115] Comparative Example 1

[0116] Unlike Example 1, the lightweight photovoltaic module does not have the microcavity composite layer 5.

[0117] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0118] Transparent front panel 1: ETFE film with a thickness of 0.025mm is selected.

[0119] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0120] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0121] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0122] Backing 6: PET backing coated with a fluorine-containing coating.

[0123] The microcavity composite layer 5 is omitted in the preparation method of the lightweight photovoltaic module, and the rest is the same as in Example 1.

[0124] Comparative Example 2

[0125] Unlike Example 1, the microcavity composite layer 5 does not contain aerogel particle powder.

[0126] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0127] Transparent front panel 1: ETFE film with a thickness of 0.025mm is selected.

[0128] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0129] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0130] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0131] Microcavity composite layer 5:

[0132] The preparation method is as follows: 10 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 10μm, PMMA), 45 parts of liquid polyurethane resin (5-3), 5 parts of crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500rpm to form a paste; it is coated on a backing plate, the wet film thickness is controlled to be about 200μm, and it is initially cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0133] Backing 6: PET backing coated with a fluorine-containing coating.

[0134] Everything else is the same as in Example 1.

[0135] Comparative Example 3

[0136] Unlike Example 1, the microcavity composite layer 5 does not contain thermoplastic polymer microspheres.

[0137] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0138] Transparent front panel 1: ETFE film with a thickness of 0.025mm is selected.

[0139] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0140] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0141] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0142] Microcavity composite layer 5:

[0143] The preparation method is as follows: 40 parts of nano-silica aerogel powder (5-1, Cabot Enova® aerogel powder, particle size 5), 45 parts of liquid polyurethane resin (5-3), 5 parts of crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500 rpm to form a paste; it is then coated onto a backing plate, with the wet film thickness controlled at approximately 200 μm, and pre-cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0144] Backing 6: PET backing coated with a fluorine-containing coating.

[0145] Everything else is the same as in Example 1.

[0146] Comparative Example 4

[0147] Unlike Example 1, the aerogel particles have a different porosity, and are replaced with aerogel particles with a porosity of 65%.

[0148] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0149] Transparent front panel 1: ETFE film with a thickness of 0.025mm is selected.

[0150] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0151] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0152] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0153] Microcavity composite layer 5:

[0154] The preparation method is as follows: 40 parts of nano-silica aerogel particle powder (5-1, particle size 5μm, porosity 65%), 10 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 10μm, PMMA), 45 parts of liquid polyurethane resin (5-3), 5 parts of curing agent / crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500rpm to form a paste; it is then coated onto a backing plate, with the wet film thickness controlled at approximately 200μm, and pre-cured in an oven at 150℃; finally, it is wound up and cured at 40℃ for 48 hours.

[0155] Backing 6: PET backing coated with a fluorine-containing coating.

[0156] Everything else is the same as in Example 1.

[0157] Comparative Example 5

[0158] Unlike Example 1, the thermoplastic polymer microspheres have a different composition, and are replaced with polystyrene copolymer foamed microspheres.

[0159] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0160] Transparent front panel 1: ETFE film with a thickness of 0.025mm is selected.

[0161] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0162] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0163] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0164] Microcavity composite layer 5:

[0165] The preparation method is as follows: 40 parts of nano-silica aerogel powder (5-1, Cabot Enova® aerogel powder, particle size 5μm, porosity 95%), 10 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 10μm, polystyrene copolymer foamed microspheres), 45 parts of liquid polyurethane resin (5-3), 5 parts of crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500 rpm to form a paste; the paste is coated onto a backing plate, the wet film thickness is controlled to be about 200μm, and it is initially cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0166] Backing 6: PET backing coated with a fluorine-containing coating.

[0167] Everything else is the same as in Example 1.

[0168] Comparative Example 6

[0169] Unlike Example 1, the mass ratio of aerogel particles, polymer foamed microspheres, and thermosetting resin matrix is ​​different, specifically: 20 parts aerogel particles, 5 parts polymer foamed microspheres, and 95 parts thermosetting resin matrix.

[0170] In the microcavity composite layer, the weight ratio of the additive components to the total weight of the aerogel particles, polymer foamed microspheres and thermosetting resin matrix remains 7:120.

[0171] A lightweight photovoltaic module with heat insulation and noise reduction functions, from the light incident surface to the back light surface, consists of:

[0172] Transparent front panel 1: ETFE film with a thickness of 0.025mm is selected.

[0173] First encapsulation layer 2: Uses a POE encapsulation film with a thickness of 0.5mm.

[0174] Photovoltaic cell 3: Conventional P-type monocrystalline silicon cells are used, cut into 182mm×182mm pieces and connected in series.

[0175] Second encapsulation layer 4: Uses a POE encapsulation film with a thickness of 0.5mm.

[0176] Microcavity composite layer 5:

[0177] The preparation method is as follows: 20 parts of nano-silica aerogel powder (5-1, Cabot Enova® aerogel powder, particle size 5, porosity 95%), 5 parts of unfoamed thermoplastic polymer microspheres (5-2, average particle size 10μm, PMMA microspheres), 95 parts of liquid polyurethane resin (5-3), 5 parts of crosslinking agent (HDI biuret, Desmodur N3390), 1 part of dispersant (BYK-161) and 1 part of defoamer (BYK-071) are mixed evenly in a high-speed mixer at 1500rpm to form a paste; the paste is coated onto a backing plate, the wet film thickness is controlled to be about 200μm, and it is initially cured in an oven at 150℃; it is then wound up and cured at 40℃ for 48 hours.

[0178] Backing 6: PET backing coated with a fluorine-containing coating.

[0179] Everything else is the same as in Example 1.

[0180] Performance testing

[0181] Thermal conductivity: Tested according to national standard GB / T 10295-2008 "Determination of steady-state thermal resistance and related properties of thermal insulation materials by heat flow meter method".

[0182] Acoustic performance: The weighted sound insulation was tested in accordance with the national standard GB / T 19889.3-2005 "Acoustics of buildings and building components - Part 3: Laboratory measurement of airborne sound insulation of building components".

[0183] Sound absorption coefficient: The sound absorption coefficient was tested in accordance with the national standard GB / T 20247-2006 "Sound absorption measurement of acoustic reverberation chamber".

[0184] The photovoltaic modules of each embodiment and each comparative example were tested for thermal conductivity, weighted sound insulation, sound absorption coefficient and weight. The test results are shown in Table 2.

[0185] Table 2

[0186]

[0187] A lower thermal conductivity indicates a poor conductor of heat, and a lower sound absorption coefficient results in better sound insulation. As shown in Table 2, the technical solution of this invention can reduce the thermal conductivity of the component, significantly blocking heat transfer, while simultaneously reducing sound propagation and providing a good noise barrier.

[0188] Finally, it should be noted that the above content is only used to illustrate the technical solution of the present invention, and is not intended to limit the scope of protection of the present invention. Simple modifications or equivalent substitutions made by those skilled in the art to the technical solution of the present invention do not depart from the essence and scope of the technical solution of the present invention.

Claims

1. A lightweight photovoltaic module with heat insulation and noise reduction functions, characterized in that, The lightweight photovoltaic module structure includes: a front panel, a first encapsulation layer, photovoltaic cells, a second encapsulation layer, a microcavity composite layer, and a back panel; The microcavity composite layer comprises the following components: aerogel particles, polymer foamed microspheres, and thermosetting resin matrix, in a mass ratio of 30-50:5-15:35-55; the porosity of the aerogel particles is 85%-99%, and the particle size of the polymer foamed microspheres is 3μm-30μm. The polymer foamed microspheres are thermoplastic polymer microspheres, and the thermoplastic polymer is selected from at least one of polymethyl methacrylate, polyacrylonitrile, and polyvinylidene chloride.

2. The lightweight photovoltaic module according to claim 1, characterized in that, The aerogel particles are selected from at least one of silica aerogel particles, alumina aerogel particles, titanium dioxide aerogel particles, and polyimide aerogel particles.

3. The lightweight photovoltaic module according to claim 1, characterized in that, The porosity of the aerogel particles is 90%-95%; the size of the aerogel particles is 5μm-25μm.

4. The lightweight photovoltaic module according to claim 1, characterized in that, The particle size of the polymer foamed microspheres is 5μm-25μm; the thermosetting resin matrix is ​​selected from at least one of polyurethane resin, polyester resin, and hydroxyl acrylic resin.

5. The lightweight photovoltaic module according to claim 1, characterized in that, The thickness of the microcavity composite layer is 50μm-300μm; The microcavity composite layer further includes an auxiliary component; the auxiliary component includes a dispersant, an antifoaming agent, and a crosslinking agent; the weight ratio of the auxiliary component in the microcavity composite layer to the total weight of the aerogel particles, polymer foamed microspheres, and thermosetting resin matrix is ​​7-12:80-95.

6. The lightweight photovoltaic module according to claim 1, characterized in that, The front panel is selected from one or more of ETFE film, PVDF film, and PET sheet; The first encapsulation layer is composed of at least one of EVA and POE; The photovoltaic cells are selected from crystalline silicon cells or perovskite cells; The second encapsulation layer is composed of at least one of EVA and POE; The backsheet is composed of at least one of PET-coated fluorocarbon resin, polypropylene fiberglass board, and epoxy fiberglass board.

7. The lightweight photovoltaic module according to claim 1, characterized in that, The thickness of the front plate is 0.02mm-0.03mm; The thickness of the first encapsulation layer or the second encapsulation layer is 0.4mm-0.6mm; The thickness of the back plate is 0.3mm-0.8mm.

8. The lightweight photovoltaic module according to any one of claims 1-7, characterized in that, The preparation method of the microcavity composite layer includes the following steps: mixing aerogel particles, polymer foamed microspheres and thermosetting resin matrix evenly, coating, and curing at 40℃-80℃ for 48h-96h to obtain the microcavity composite layer.

9. A method for preparing a lightweight photovoltaic module according to any one of claims 1-8, characterized in that, The steps include: stacking the front panel (1), the first encapsulation layer (2), the photovoltaic cell (3), the second encapsulation layer (4), the microcavity composite layer (5), and the back panel (6) in the above order, sending the stacked module into a laminator for lamination, vacuuming and heating during lamination; and then cooling to obtain a lightweight photovoltaic module.

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