Flexible photovoltaic module BIPV system for curved building

Abstract

The invention relates to the technical field of building integrated photovoltaics (BIPV), and provides a flexible photovoltaic module BIPV system for a curved surface building. Comprising a surface weather-resistant high-molecular material, a first layer of adhesive film, a first layer of inorganic high-molecular reinforcing material, a battery piece, a second layer of inorganic high-molecular reinforcing material, a second layer of adhesive film and a back plate weather-resistant high-molecular material which are sequentially stacked from top to bottom, the first layer of inorganic high-molecular reinforcing material and the second layer of inorganic high-molecular reinforcing material are respectively positioned on the upper side and the lower side of the battery piece, and the unfilled part is filled with the adhesive film; the surface weather-resistant high polymer material is used as the outer surface of the flexible assembly and has high light transmittance and weather resistance; the backboard weather-resistant high polymer material is used as an assembly backboard and has weather resistance; the first layer of adhesive film and the second layer of adhesive film are used for bonding all the parts together and have water resistance and weather resistance; and the flexible photovoltaic module is laminated through a laminating machine with a double-cavity structure.

Description

Technical Field

[0001] This invention belongs to the field of building-integrated photovoltaics (BIPV) technology, specifically relating to a flexible photovoltaic module BIPV system for curved buildings. Background Technology

[0002] Building-integrated photovoltaics (BIPV) technology combines photovoltaic modules with building structures, achieving a fusion of power generation and architectural aesthetics. However, traditional BIPV systems face significant challenges in curved building designs: existing photovoltaic modules are mostly rigid double-glazed structures of "glass-encapsulant-cell-encapsulant-glass," which are limited by the physical properties of glass and cannot be bent, making it difficult to conform to the complex shapes of curved buildings and severely restricting application scenarios. Although flexible photovoltaic modules have emerged in the market, existing solutions generally suffer from two core flaws: first, using a single layer of reinforcing material (such as fiberglass) to protect the cells only allows for small-angle bending; at large angles, the cells are prone to breakage due to stress concentration; second, the lamination process does not address the issue of filling the edges of the reinforcing material with the edges of the module, resulting in uneven module surfaces that affect appearance and lifespan. Furthermore, existing technologies have not proposed an effective combination of double-layer reinforcing material configurations and differentiated lamination processes. Summary of the Invention

[0003] This application provides a rapid assembly process for photovoltaic module frames, aiming to solve the significant challenges faced by traditional BIPV systems in curved building designs: existing photovoltaic modules are mostly double-glass rigid structures of "glass-encapsulant-cell-encapsulant-glass", which cannot be bent due to the physical properties of glass, making it difficult to fit the complex shape of curved buildings, resulting in severely limited application scenarios.

[0004] In a first aspect, this application provides a flexible photovoltaic module BIPV system for curved buildings, comprising, from top to bottom, a surface weather-resistant polymer material, a first layer of encapsulant film, a first layer of inorganic polymer reinforcing material, a solar cell, a second layer of inorganic polymer reinforcing material, a second layer of encapsulant film, and a backsheet weather-resistant polymer material. The first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material are located on the upper and lower sides of the battery cell, respectively. The area of ​​the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material is smaller than the size of the surface weather-resistant polymer material, the first layer of adhesive film, the battery cell, the second layer of adhesive film and the backsheet weather-resistant polymer material. The unfilled part is filled by the adhesive film. The surface weather-resistant polymer material serves as the outer surface of the flexible module, exhibiting high light transmittance and weather resistance. The backsheet weather-resistant polymer material serves as the module backsheet, possessing weather resistance. The first layer of adhesive film is used to bond the weather-resistant polymer material, the first layer of inorganic polymer reinforcing material, and the solar cells. The second layer of adhesive film is used to bond the solar cells, the second layer of adhesive film, and the backsheet weather-resistant polymer material. Both the first and second layers of adhesive film possess water resistance and weather resistance. The flexible photovoltaic module is laminated using a dual-cavity laminator. The upper heating temperature of the first cavity is 85-95℃, and the lower heating temperature of the first cavity is 115-128℃. The upper heating temperature of the second cavity is 85-95℃, and the lower heating temperature of the second cavity is 149-159℃. The lamination time for the first cavity is 10-13 minutes, and the lamination time for the second cavity is 10-13 minutes.

[0005] In some embodiments, during lamination, a high-temperature cloth is first laid on the substrate, and the surface weather-resistant polymer material, the first layer of adhesive film, the first layer of inorganic polymer reinforcing material, the battery cell, the second layer of inorganic polymer reinforcing material, the second layer of adhesive film, and the backsheet weather-resistant polymer material are cut and stacked according to standard dimensions and then put into the laminator for lamination. The substrate is made of semi-tempered glass or fiberglass board to provide flat conditions for lamination.

[0006] In some embodiments, the edges of the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material extend outward by 2-3 mm relative to the edge of the battery cell, and are smaller than the edge dimensions of the surface weather-resistant polymer material, the first layer of adhesive film, the second layer of adhesive film and the backsheet weather-resistant polymer material, so as to form an unfilled area at the edge of the component.

[0007] In some embodiments, the slope of the component edges after lamination is eliminated by covering and filling the area between the edges of the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material and the edges of the surface weather-resistant polymer material and the backsheet weather-resistant polymer material with an adhesive film, thereby ensuring the overall flatness of the component.

[0008] In some embodiments, the surface weather-resistant polymer material is a fluoropolymer with a light transmittance of not less than 92%, which can resist ultraviolet aging and has a hydrophobic surface to reduce dust adhesion and improve self-cleaning ability.

[0009] In some embodiments, the weather-resistant polymer material of the back panel is PET, which has water vapor barrier properties and chemical corrosion resistance, and can resist acid rain and salt spray erosion, meeting the requirements for long-term outdoor use; wherein, the water vapor permeability is ≤0.5g / m 2 *day.

[0010] In some embodiments, the first and second adhesive films are POE films with a light transmittance of not less than 92% and a water vapor transmittance of less than 0.5 g / m³.2 *day achieves high-strength adhesion and long-term weather resistance of each layer of material through molecular structure design.

[0011] In some embodiments, a composite reinforcing material is further disposed between the surface weather-resistant polymer material and the first layer of inorganic polymer reinforcing material, and the first layer of adhesive film is used to sequentially bond the surface weather-resistant polymer material, the composite reinforcing material and the first layer of inorganic polymer reinforcing material; the composite reinforcing material is used to improve the surface smoothness of the component and enhance its impact resistance.

[0012] In some embodiments, during the lamination process, the dual-chamber laminator performs segmented pressure control in one chamber: a vacuuming time of 700-730 seconds, followed by a first pressure holding of -70KPa to -60KPa, a second pressure holding of -45KPa to -35KPa, and a third pressure holding of -10KPa to -5KPa; the second chamber is vacuumed for 80-90 seconds, and the gradient pressure change achieves uniform melting of the adhesive film and tight bonding of each layer of material, improving the consistency of component lamination.

[0013] In some embodiments, the junction box installation position of the flexible photovoltaic module is adjusted according to the adaptability of the installation surface: when on an aluminum panel curtain wall surface, the junction box is installed on the front of the flexible module; when on a corrugated steel tile or concrete surface, the junction box is installed on the back of the flexible module and hidden in the gaps of the corrugations or keels, ensuring the aesthetics and safety of the installation structure.

[0014] This invention utilizes a double-layer inorganic polymer reinforcement material symmetrically arranged on the top and bottom sides of the solar cell. Compared to existing single-layer structures, this increases the bending strength to ≥120MPa and the elongation at break to ≥15%, enabling the module to achieve a bending radius of up to 0.5m, meeting the fitting requirements of large-angle curved buildings. Simultaneously, the double-sided support evenly distributes bending stress, preventing cell breakage. By filling the edges not covered by the reinforcement material with an adhesive film, the slope of the module edges after lamination is eliminated. Combined with the flat lamination conditions provided by the substrate (semi-tempered glass / fiberglass board), this ensures a pit-free module surface, improving appearance quality and installation compatibility. Furthermore, the weather-resistant design of the fluorinated surface material and the PET backsheet (resistant to UV yellowing and salt spray corrosion) extends the module's lifespan. Differential temperature control in a dual-chamber laminator (low-temperature preheating in one chamber, high-temperature curing in the second chamber) combined with a segmented pressure process achieves gradient melting of the POE adhesive film and tight adhesion between each layer, reducing bubbles and delamination defects and improving the module's electrical performance stability.

[0015] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of a first type of flexible photovoltaic module BIPV system for curved buildings provided in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a second type of flexible photovoltaic module BIPV system for curved buildings provided in an embodiment of this application.

[0018] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the described order. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0021] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present invention, the terms "first" and "second" are used in the embodiments of the present invention to distinguish identical or similar items with essentially the same function and effect. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0022] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0023] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0024] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0025] Building-integrated photovoltaics (BIPV) technology combines photovoltaic modules with building structures, achieving a fusion of power generation and architectural aesthetics. However, traditional BIPV systems face significant challenges in curved building designs: existing photovoltaic modules are mostly rigid double-glazed structures of "glass-encapsulant-cell-encapsulant-glass," which are limited by the physical properties of glass and cannot be bent, making it difficult to fit the complex shapes of curved buildings and severely restricting application scenarios. Although flexible photovoltaic modules have emerged in the market, existing solutions generally suffer from two core flaws: first, using a single layer of reinforcing material (such as fiberglass) to protect the cells only allows for small-angle bending; at large angles, the cells are prone to breakage due to stress concentration; second, the lamination process does not address the issue of filling the edges of the reinforcing material with the module edges, resulting in uneven module surfaces that affect appearance and lifespan. Furthermore, existing technologies have not proposed an effective combination of double-layer reinforcing material configurations and differentiated lamination processes. The problems and shortcomings of existing technologies include: 1. Limitations of Rigid Structures and Single-Layer Reinforcement Materials: Traditional double-glass modules rely on glass as the encapsulation material, which is completely inflexible, directly excluding its application in curved buildings. Some flexible modules have attempted to use single-layer inorganic polymer reinforcement materials (such as glass fiber) to replace glass, but the mechanical strength of a single-layer structure is insufficient (bending strength is typically <100MPa, elongation at break <10%). When the bending radius is less than 1m, the solar cells shatter due to the lack of double-sided support, failing to meet the large-angle bending requirements of curved buildings (such as arched roofs, hyperboloid curtain walls, etc.).

[0026] 2. Defects in Lamination Process and Structural Design: In existing flexible modules, if the reinforcing material area is smaller than the overall module size during lamination, unfilled edges can cause slopes or pits on the laminated module surface, affecting appearance and installation compatibility. Some manufacturers cover up defects with surface embossing, but this does not solve the fundamental problem; using full-size reinforcing material increases costs and sacrifices flexibility. Furthermore, traditional laminators use single temperature and pressure parameters, failing to balance the uniformity of adhesive film melting and material bonding strength, leading to problems such as internal bubbles and delamination, further reducing reliability.

[0027] To resolve the above issues, please refer to [link / reference]. Figure 1This application provides a flexible photovoltaic module BIPV system for curved buildings, comprising, from top to bottom, a surface weather-resistant polymer material 1, a first layer of adhesive film 2, a first layer of inorganic polymer reinforcement material 3, a solar cell 4, a second layer of inorganic polymer reinforcement material 5, a second layer of adhesive film 6, and a backsheet weather-resistant polymer material 7; the first and second layers of inorganic polymer reinforcement material are located on the upper and lower sides of the solar cell, respectively, and the areas of both the first and second layers of inorganic polymer reinforcement material are smaller than the dimensions of the surface weather-resistant polymer material, the first layer of adhesive film, the solar cell, the second layer of adhesive film, and the backsheet weather-resistant polymer material, with the unfilled portion filled by the adhesive film; the surface weather-resistant polymer material serves as the flexible... The outer surface of the flexible photovoltaic module has high light transmittance and weather resistance; the backsheet, made of weather-resistant polymer material, serves as the module's backsheet and is weather-resistant; the first layer of adhesive film is used to bond the weather-resistant polymer material, the first layer of inorganic polymer reinforcing material, and the solar cells; the second layer of adhesive film is used to bond the solar cells, the second layer of adhesive film, and the backsheet's weather-resistant polymer material, and both the first and second layers of adhesive film are water-resistant and weather-resistant; the flexible photovoltaic module is laminated using a dual-cavity laminator, with the upper heating temperature of the first cavity at 85-95℃ and the lower heating temperature of the first cavity at 115-128℃, the upper heating temperature of the second cavity at 85-95℃, and the lower heating temperature of the second cavity at 149-159℃, and the lamination time of the first cavity and the second cavity both at 10-13 minutes.

[0028] Specifically, this invention provides a flexible photovoltaic module BIPV system suitable for curved buildings. By combining double-layer inorganic polymer reinforcement materials with differentiated lamination processes, it solves the problems of traditional rigid double-glass modules being unable to bend and existing flexible modules being prone to breakage and having uneven surfaces when bent at large angles, thus achieving efficient integration of photovoltaic modules with curved buildings.

[0029] The module structure design (double-layer reinforcement protection) adopts a multi-layer composite stacked structure. With the solar cell at the center, inorganic polymer reinforcement materials (such as glass fiber reinforcement materials) are symmetrically arranged on the upper and lower sides, forming a "double-sided support and protection." The specific structure is as follows (from top to bottom): Surface weather-resistant polymer material (such as fluoropolymer): high light transmittance (≥92%), UV resistant (high CF bond energy, photodegradation resistant), hydrophobic and self-cleaning, serving as the outer surface protective layer. First layer encapsulant film (POE film): bonds the surface material to the upper reinforcement material, and blocks water (water vapor transmission rate <0.5g / m²). 2*day), weather-resistant, and prevents yellowing. First layer: Inorganic polymer reinforcement material: Area smaller than the module size (only 2-3mm larger than the solar cell), protects the upper surface of the solar cell, disperses bending stress, and improves impact resistance (such as hail impact). Solar cell: The core power generation unit, sandwiched between the two layers of reinforcement material. Second layer: Inorganic polymer reinforcement material: Symmetrical to the upper layer, protects the lower surface of the solar cell, forms double-sided mechanical support, significantly improves bending strength (≥120MPa) and elongation at break (≥15%), allowing a bending radius as low as 0.5m. Second layer: Adhesive film (POE film): Bonds the lower reinforcement material to the backsheet, functioning the same as the first layer. Backsheet weather-resistant polymer material (such as PET): Resistant to chemical corrosion (salt spray test >1000 hours), moisture barrier, protecting the back of the solar cell.

[0030] The double-layer reinforcement material differs from existing single-layer glass fiber solutions (such as Seraphim). Double-sided support reduces stress concentration in the cells and adapts to large-angle bending. The edge-filled reinforcing film fills the areas not covered by the reinforcement material, and the lamination eliminates the edge slope, ensuring a smooth module surface (without pits) and avoiding the problem of existing technologies using embossing to cover defects.

[0031] The differentiated lamination process (dual-cavity laminator) uses a dual-cavity laminator to achieve uniform melting and tight bonding of the adhesive film with the material through segmented temperature and pressure control. Specific parameters (partially confidential): First cavity temperature: upper heating 85-95℃, lower heating 115-128℃, lamination time 10-13 minutes; Second cavity temperature: upper heating 85-95℃, lower heating 149-159℃, lamination time 10-13 minutes; Pressure control: three-stage vacuum pressure holding (-70KPa→-45KPa→-10KPa) to ensure that the melted adhesive film fills the gaps at the edges of the reinforcing material, eliminates bubbles and delamination, and improves the overall integrity of the component.

[0032] Three installation schemes are designed based on the building surface material to ensure flexible fit and concealment of the junction box: Aluminum panel curtain wall: Structural adhesive is fully applied to the back panel for direct pasting, and the junction box is exposed on the front (suitable for flat curved surfaces); Corrugated steel sheet: Pasted onto the corrugated surface, and the junction box is hidden in the gaps between the corrugations (suitable for wavy curved surfaces); Concrete surface: Leveled by keel, pasted onto the keel, and the junction box is hidden in the gaps between the keel (suitable for complex curved surfaces).

[0033] For example, the material configuration and functions are shown in the table below: The processing flow includes: Substrate preparation: using semi-tempered glass or fiberglass board as the substrate to provide a flat lamination base and avoid pits on the module surface; Material cutting: cutting each layer of material according to size (e.g., 1128×2272mm), with the reinforcing material size only 2-3mm larger than the solar cell; Lamination: stacking surface material → adhesive film → upper reinforcing material → solar cell → lower reinforcing material → adhesive film → backsheet on the high-temperature cloth of the substrate in sequence; Dual-cavity lamination: First-cavity pre-pressing: low temperature (lower cavity 115-128℃) to initially melt the adhesive film and fix the position of each layer; Second-cavity high pressure: high temperature (lower cavity 149-159℃) to completely melt the adhesive film, fill the gaps at the edges of the reinforcing material, and hold pressure for 10-13 minutes; Cooling and demolding: natural cooling after lamination, removing the substrate to form a flexible module with a flat surface.

[0034] Application scenarios include: renovation of old buildings: flexible components reduce the load on facades / roofs with weak load-bearing capacity; new curved buildings: complex structures such as curved curtain walls and hyperboloid roofs, realizing integrated BIPV design; special scenarios: irregular surfaces such as color steel tiles and aluminum panels, which can be quickly adapted through adhesive installation.

[0035] In some embodiments, during lamination, a high-temperature cloth is first laid on the substrate, and the surface weather-resistant polymer material, the first layer of adhesive film, the first layer of inorganic polymer reinforcing material, the battery cell, the second layer of inorganic polymer reinforcing material, the second layer of adhesive film, and the backsheet weather-resistant polymer material are cut and stacked according to standard dimensions and then put into the laminator for lamination. The substrate is made of semi-tempered glass or fiberglass board to provide flat conditions for lamination.

[0036] By combining a substrate (semi-tempered glass or fiberglass board) and a high-temperature cloth, a flat base is provided for the lamination process, ensuring that the surface of the flexible component is free of pits and defects.

[0037] Substrate Selection: Semi-tempered glass (high strength, good flatness) or fiberglass board (lightweight, high temperature resistance) is used as the lamination substrate, with dimensions slightly larger than the module design size (e.g., 1128×2272mm). High-Temperature Fabric Laying: A layer of high-temperature resistant silicone rubber cloth (0.3-0.5mm thick) is evenly laid on the substrate surface to prevent materials from sticking to the substrate during lamination and to assist in heat conduction. Material Lamination: The following layers are laid on the high-temperature cloth in sequence: surface weather-resistant polymer material → first layer of adhesive film → first layer of reinforcing material → solar cell → second layer of reinforcing material → second layer of adhesive film → backsheet material. The edges of each layer are aligned with an error ≤1mm. Lamination Preparation: The laminated substrate is placed in a dual-cavity laminator, ensuring that the substrate is parallel to the laminator table to avoid uneven edges caused by tilting.

[0038] In some embodiments, the edges of the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material extend outward by 2-3 mm relative to the edge of the battery cell, and are smaller than the edge dimensions of the surface weather-resistant polymer material, the first layer of adhesive film, the second layer of adhesive film and the backsheet weather-resistant polymer material, so as to form an unfilled area at the edge of the component.

[0039] By controlling the edge size of the inorganic polymer reinforcement material (extending only 2-3mm beyond the solar cell), an unfilled area is formed at the edge of the module, providing space for the encapsulant film to fill.

[0040] The dimensional design includes: Cell size: assumed to be 1000×2000mm, with cutting allowance at the edges; First / Second layer reinforcement material size: 1004×2004mm (2mm beyond the cell on each side); Surface weather-resistant material / backsheet material size: 1128×2272mm (standard module size), with the encapsulant film size consistent with the surface material. Edge difference: The distance between the edge of the reinforcement material and the edge of the surface material is 62mm (one side), forming an unfilled area (62mm wide) for natural filling after the encapsulant film melts. Cutting accuracy: The reinforcement material is cut using a CNC cutting machine, with an edge perpendicularity error ≤0.5mm, ensuring symmetry during stacking.

[0041] In some embodiments, the slope of the component edges after lamination is eliminated by covering and filling the area between the edges of the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material and the edges of the surface weather-resistant polymer material and the backsheet weather-resistant polymer material with an adhesive film, thereby ensuring the overall flatness of the component.

[0042] The fluidity of the melted adhesive film is used to fill the gap between the edges of the reinforcing material and the components, eliminating the edge slope after lamination and ensuring a smooth surface.

[0043] The adhesive film coverage design includes: the first / second layer adhesive film has the same size as the surface material / backsheet (1128×2272mm), completely covering the unfilled area of ​​the reinforcing material (62mm edge).

[0044] Lamination and Melting Process: During the two-cavity high-temperature lamination stage (lower cavity 149-159℃), the POE film melts (melting point approximately 120℃). The liquid film flows towards the unfilled edges, filling the gaps between the reinforcing material and the surface material. Pressure Control: Three pressure-holding stages (-10KPa to -5KPa) provide continuous pressure to ensure uniform filling of the film and prevent air bubble residue. Flatness Inspection: After lamination, the surface is inspected using a 3D scanner. The flatness deviation at the edges is ≤0.3mm, with no visible slope.

[0045] In some embodiments, the surface weather-resistant polymer material is a fluoropolymer with a light transmittance of not less than 92%, which can resist ultraviolet aging and has a hydrophobic surface to reduce dust adhesion and improve self-cleaning ability.

[0046] Fluoropolymers are used as the outer surface material to achieve high light transmittance, UV resistance, and self-cleaning properties. Material selection: Polyvinylidene fluoride (PVDF) or ethylene-tetrafluoroethylene copolymer (ETFE) is preferred, with a thickness of 0.2-0.3 mm and a light transmittance ≥92% (test wavelength 300-1100 nm). Surface treatment: Corona treatment enhances surface polarity and strengthens adhesion to the POE film (peel strength ≥30 N / cm); Self-cleaning design: The surface is coated with a nano-titanium dioxide coating (5-10 μm thick), which utilizes photocatalytic effect to decompose dust and organic matter, with a hydrophobic contact angle ≥110°, reducing the frequency of manual cleaning.

[0047] In some embodiments, the weather-resistant polymer material of the back panel is PET, which has water vapor barrier properties and chemical corrosion resistance, and can resist acid rain and salt spray erosion, meeting the requirements for long-term outdoor use; wherein, the water vapor permeability is ≤0.5g / m 2 *day.

[0048] Using PET material as the backsheet achieves moisture barrier and chemical corrosion resistance, ensuring the long-term stability of the battery cells.

[0049] Material parameters: PET film with double-sided weather-resistant coating, 0.3mm thickness, and water vapor permeability ≤0.5g / m². 2 *day, salt spray corrosion test >1000 hours, no discoloration or cracking. The back panel edge is aligned with the surface material edge and bonded to the underlying structure via POE film. An additional sealant (silicone adhesive) is applied to the edges to prevent moisture penetration. Periodic sampling is performed for damp heat cycling (85℃ / 85%RH, 1000 hours), and the back panel shows no delamination or degradation, with a moisture permeability change ≤5%.

[0050] In some embodiments, the first and second adhesive films are POE films with a light transmittance of not less than 92% and a water vapor transmittance of less than 0.5 g / m³. 2 *day achieves high-strength adhesion and long-term weather resistance of each layer of material through molecular structure design.

[0051] By employing ethylene-octene copolymer (POE) film, high light transmittance, low water vapor transmittance, and high-strength interlayer adhesion are achieved. Film parameters: thickness 0.5mm, light transmittance ≥92%, melt flow rate (MFR) 15-20g / 10min (190℃, 2.16kg), ensuring good fluidity after melting. Bonding process: During lamination, the film melts in the range of 115-159℃, forming a chemical crosslink with the fluorinated surface, glass fiber reinforcement, and PET backing, achieving a peel strength ≥40N / cm (ASTM D3330 test). Weather resistance advantage: Compared to traditional EVA film (light transmittance 88%, water vapor transmittance 1g / m²), weather resistance is significantly improved. 2* POE film has a yellowing index ≤5 under UV irradiation (EVA yellowing index ≥15), extending the module life by 5-8 years.

[0052] In some embodiments, such as Figure 2 As shown, a composite reinforcing material 8 is also provided between the surface weather-resistant polymer material and the first layer of inorganic polymer reinforcing material. The first layer of adhesive film is used to sequentially bond the surface weather-resistant polymer material, the composite reinforcing material and the first layer of inorganic polymer reinforcing material. The composite reinforcing material is used to improve the surface smoothness of the component and enhance its impact resistance.

[0053] By adding a composite reinforcing material between the surface weather-resistant material and the upper reinforcing material, surface smoothness and impact resistance are improved. Material composition: The composite reinforcing material uses a "PET film + glass microsphere coating" with a thickness of 0.2 mm and a surface roughness Ra ≤ 1.0 μm, ensuring a smooth outer surface of the component. Lamination structure: Surface weather-resistant material → First layer adhesive film → Composite reinforcing material → First layer adhesive film → First layer reinforcing material (original structure adjusted to: Surface layer → Adhesive film → Composite reinforcing material → Adhesive film → Reinforcing material). Functional achievement: The composite reinforcing material fills the tiny depressions on the surface with uniformly distributed glass microspheres (50-100 μm in diameter). After lamination, the surface smoothness error is ≤ 0.2 mm, while simultaneously improving hail impact resistance (able to withstand hailstones with a diameter of 25 mm and an impact velocity of 23 m / s).

[0054] In some embodiments, during the lamination process, the dual-chamber laminator performs segmented pressure control in one chamber: a vacuuming time of 700-730 seconds, followed by a first pressure holding of -70KPa to -60KPa, a second pressure holding of -45KPa to -35KPa, and a third pressure holding of -10KPa to -5KPa; the second chamber is vacuumed for 80-90 seconds, and the gradient pressure change achieves uniform melting of the adhesive film and tight bonding of each layer of material, improving the consistency of component lamination.

[0055] By controlling the gradient pressure of a dual-cavity laminator, the adhesive film is uniformly melted and tightly bonded to each layer of material, thus improving lamination consistency.

[0056] First chamber (pre-compression chamber) parameters: Vacuuming time: 700-730 seconds (approximately 11.7-12.2 minutes), ensuring that the air residual rate in the chamber is <0.1%; Pressure stages: First pressure holding: -70KPa to -60KPa, lasting for 10 seconds, to initially fix the position of each layer; Second pressure holding: -45KPa to -35KPa, lasting for 10 seconds, to promote the initial melting of the film edge; Third pressure holding: -10KPa to -5KPa, lasting for 100 seconds, to enable the reinforcing material to initially bond with the solar cell.

[0057] Second-chamber (high-pressure chamber) parameters: Vacuuming time: 80-90 seconds, quickly establishing a vacuum environment; Pressure segmentation: Similar to the first chamber, but the three pressure holding times are extended to 720-750 seconds (12-12.5 minutes), combined with the high temperature of the lower chamber (149-159℃), ensuring that the adhesive film completely melts and fills the edge gaps. Pressure control accuracy: Real-time monitoring via pressure sensor, with an error of ±2KPa, avoiding material deformation due to overpressure or delamination due to underpressure.

[0058] In some embodiments, the junction box installation position of the flexible photovoltaic module is adjusted according to the adaptability of the installation surface: when on an aluminum panel curtain wall surface, the junction box is installed on the front of the flexible module; when on a corrugated steel tile or concrete surface, the junction box is installed on the back of the flexible module and hidden in the gaps of the corrugations or keels, ensuring the aesthetics and safety of the installation structure.

[0059] Adjust the junction box position according to the type of installation surface to balance aesthetics and safety, and avoid damage to exposed wiring.

[0060] Aluminum panel curtain wall scenarios include: Junction box model: Use ultra-thin waterproof junction boxes (thickness ≤15mm), installed on the non-transparent area of ​​the front edge of the component (such as the frame); Connection method: Adhere the junction box base to the surface of the component with structural adhesive (silicone glue), lead the wires out from the edge, and cover the outside with waterproof strips of the same color to maintain a uniform appearance.

[0061] The corrugated steel roofing system includes: Junction box location: Installed on the back of the component in the corrugated gaps (corrugation depth ≥ 20mm), utilizing the corrugated structure to conceal the junction box; Protective design: The junction box surface is covered with a metal cover plate of the same color as the corrugated steel roofing sheet, and the edges are sealed with waterproof sealant. The wires are arranged along the corrugated grooves to avoid exposure to rainwater impact. Concrete surface (keel installation): Keel spacing: The keel spacing is designed according to the component size (e.g., 600mm × 600mm grid). The junction box is installed at the keel intersection gap (leaving a 50mm × 50mm space); Concealment treatment: The junction box is wrapped with insulation material, and the surface is covered with a decorative panel of the same material as the building. A quick-release structure facilitates later maintenance, and the wires are laid through conduits inside the keel.

[0062] In some embodiments, by using historical lamination data to train a neural network model, the temperature, pressure, and time parameters of the dual-cavity laminator are optimized in real time, solving the problem of yield fluctuation caused by the reliance on manual experience for adjustment in traditional processes, and realizing intelligent control of the flexible component lamination process.

[0063] Data acquisition and annotation include: Sensor deployment: Thermocouples (accuracy ±0.5℃), pressure sensors (accuracy ±1KPa), and infrared cameras (monitoring the melting state of the adhesive film) are installed in the laminator cavity to collect temperature curves (upper / lower cavities), pressure changes, time parameters, and final component defect data (such as bubble rate and edge slope) for each batch of lamination. Sample annotation: Over 100,000 batches of data are accumulated, labeled as "good" (no defects) and "bad" (bubbles / delamination / unevenness), to construct a training dataset.

[0064] The algorithm model is constructed using a hybrid neural network of LSTM and CNN: LSTM processes the sequential data of temperature / pressure changes over time, and CNN analyzes the features of infrared images to output the optimal combination of parameters (temperature compensation coefficient, pressure segmentation threshold, and pressure holding time correction value).

[0065] Training strategy: Use the Adam optimizer, with the loss function being cross-entropy + mean squared error (taking into account both classification and regression tasks), and update the model every 500 batches of data.

[0066] Real-time control process: Input the current component model (such as bending radius requirements) and material batch (including fluoropolymer thickness and POE film MFR value), and the model will automatically generate initial parameters; real-time data is collected every 10 seconds during the lamination process and compared with the ideal curve predicted by the model. The heating power and vacuum pump speed are dynamically adjusted through the PID controller to ensure that the parameter deviation is ≤2%.

[0067] In some embodiments, by scanning the surface of the laminated component with a linear scan camera and combining it with a deep learning model, defects such as micro-cracks, film bubbles, and uneven edges are automatically identified, replacing manual visual inspection and solving the problems of high missed detection rate and strong subjectivity in traditional inspection.

[0068] The hardware deployment includes: Inspection platform: A high-precision linear scan camera (12K resolution, 500mm / s scanning speed) is installed at the laminator outlet, coupled with a parallel backlight (5500K color temperature, uniformity ≥98%), to achieve 0.1mm-level precision imaging of the component surface. Edge detection: Focused scanning is performed on the component edge area (62mm wide encapsulation filling area), improving the resolution to 0.05mm / pixel.

[0069] The algorithm model construction includes: Backbone network: Improved YOLOv8-nano (lightweight model, inference speed ≥100FPS), introducing an edge attention module to enhance the feature extraction ability of edge slope and small bubbles; Defect classification: The training set contains multiple defect images (cracks, bubbles, slope >0.5mm, edge delamination), and Focal Loss is used to balance positive and negative samples, achieving mAP@0.5 of over 95%.

[0070] The inspection process includes: image preprocessing: removing background noise through threshold segmentation and morphological filtering, and automatically locating the edges of the reinforcing material and the film filling area; defect judgment: identifying air bubbles (area > 0.5 mm). 2 Cracks (length > 1 mm) and edge slopes (calculated using 3D point cloud data, deviation > 0.3 mm) are marked in real time, generating a heat map of the defect location; closed-loop control: the detection results are fed back to the laminator parameter optimization model, automatically correcting the pressure / temperature parameters for the next batch.

[0071] In some embodiments, for complex curved building surfaces (such as hyperboloid roofs and curved curtain walls), the optimal distribution of pasting points and junction box concealment schemes are automatically generated using three-dimensional point cloud data and particle swarm optimization (PSO) algorithms, solving the problems of stress concentration and messy wiring in traditional manual design and installation.

[0072] Architectural Surface Modeling: Data Acquisition: Use a 3D laser scanner (accuracy ±1mm) to scan the building surface and acquire point cloud data (density ≥50 points / cm²). 2 The surface model was reconstructed using MeshLab software (STL format). Curvature analysis: The curvature radius (Gaussian curvature, mean curvature) of each region of the surface was calculated, and the surface was divided into "smooth region" (curvature radius > 2m), "medium curvature region" (0.5-2m), and "large curvature region" (< 0.5m), and the bending performance of the components was matched (minimum radius 0.5m).

[0073] The optimization algorithm design includes: Objective function: Mechanical equilibrium: Minimize the variance of stress distribution at the bonding points (avoid local overload); Shortest wiring: Minimize the wire length from the junction box to the combiner box (reduce line loss); Concealment: The probability that the junction box is located in a curved surface depression or structural joint (such as corrugated steel sheet or keel gap) is ≥90%. Constraints: Bonding point spacing ≥300mm (avoid stress superposition of adhesive film), junction box installation area depth ≥20mm (to accommodate a junction box thickness of 15mm). The algorithm implementation adopts an improved PSO algorithm, with particle dimensions being the bonding point coordinates (x, y, z) and the junction box position index. Simulated annealing (SA) is used to avoid local optima, and convergence is achieved within 500 iterations.

[0074] The installation plan generation includes: Output results: including the coordinates of the pasting point (accuracy ±2mm), the amount of structural adhesive used (error ≤5%), the junction box model (automatically matched to ultra-thin / standard type according to the installation depth), and a 3D diagram of the wire routing (avoiding areas of concentrated building stress); Visual verification: through Unity3D simulation of the component bending and bonding process, detect whether there are wrinkles or gaps (an alarm will be triggered if the gap is >0.5mm).

[0075] In some embodiments, by integrating micro-sensors (strain gauges, temperature sensors) inside the flexible component, bending stress and temperature data are collected in real time through edge computing nodes, and recurrent neural networks (RNNs) are used to predict the risk of cell cracking and film delamination, thereby enabling preventive maintenance.

[0076] The sensor deployment includes: strain gauges: two micro strain gauges (2mm×2mm in size, ±0.1% accuracy) are attached to the upper and lower surfaces of the solar cell to monitor the stress distribution during bending (key areas: the gap between the edge of the reinforcing material and the solar cell); temperature sensors: three NTC thermistors (±0.5℃ accuracy) are embedded in the adhesive film layer to monitor the internal temperature changes of the module (especially the heat-prone areas near the junction box).

[0077] The edge computing and cloud architecture includes: edge nodes using low-power STM32 microcontrollers, which collect sensor data every 10 minutes, remove noise through wavelet transform, and extract feature parameters such as stress fluctuation amplitude and temperature change rate; cloud model: trained using LSTM-RNN model, with input features including historical 7-day stress-time series, temperature-time series, and ambient humidity, and outputting the defect probability for the next 24 hours (early warning triggered when crack probability > 15% and delamination probability > 10%).

[0078] The maintenance strategy includes: Level 1 warning (probability 10%-20%): Sending SMS notifications to maintenance personnel and automatically retrieving the curvature data of the mounting surface of the component to analyze whether stress concentration is caused by excessive bending; Level 2 warning (probability > 20%): Linking with the drone inspection system (equipped with an infrared thermal imager) to detect areas with abnormal surface temperature of the component, and after confirmation, dispatching a robot to perform local structural adhesive reinforcement (without disassembling the component).

[0079] In some embodiments, by constructing a digital twin model of a flexible photovoltaic module and combining it with a genetic algorithm (GA) to optimize parameters such as the thickness of the double-layer reinforcement material, the edge extension size, and the encapsulant formulation, the problems of long development cycles and serious material waste associated with traditional trial-and-error methods can be solved.

[0080] Digital twin modeling includes: Multiphysics simulation: using COMSOL Multiphysics to build a three-layer structural model (surface layer - reinforcement layer - solar cell - reinforcement layer - backsheet layer), coupled with mechanical (bending stress), optical (transmittance attenuation), and thermal (temperature distribution) simulation modules; Material library: inputting measured parameters (elastic modulus, coefficient of thermal expansion, transmittance spectrum curves) of fluoropolymers, POE films, and glass fiber reinforced materials, with an error ≤3%.

[0081] The optimization variables corresponding to the genetic algorithm optimization include: the thickness of the reinforcing material (0.3-0.8 mm, step size 0.1 mm); the edge extension size (1-5 mm, step size 1 mm); and the degree of crosslinking of the POE film (60%-90%, adjusted by the amount of peroxide added).

[0082] Fitness function: f = 0.4 × bending strength / target value + 0.3 × light transmittance + 0.2 × 1 / production cost + 0.1 × predicted weathering life; The algorithm process includes: population size 50, 100 iterations, crossover probability 0.8, mutation probability 0.05, and 100 simulations per generation using a digital twin model to select the optimal parameter combination.

[0083] In some embodiments, the processing technology includes: Equipment: a laminator, which lays a high-temperature cloth on a substrate (materials such as glass and fiberglass to provide flat lamination conditions and ensure a smooth, pit-free surface for the component), and then cuts and stacks the materials described in the product configuration according to the required standard dimensions before lamination in the laminator. The laminator used is a dual-chamber structure. The upper heating temperature of the first chamber is 85-95℃, and the lower heating temperature of the first chamber is 115-128℃. The upper heating temperature of the second chamber is 85-95℃, and the lower heating temperature of the second chamber is 149-159℃. The lamination time for the first chamber is 10-13 minutes, and the lamination time for the second chamber is 10-13 minutes. (Parameters are kept confidential). Application scenarios include photovoltaic renovation of the facades and roofs of old buildings with weak load-bearing capacity; and renovation of the facades and roofs of new buildings.

[0084] Installation methods include: On aluminum panel curtain walls: Structural adhesive is fully applied to the back panel of the flexible component, which is then directly adhered to the aluminum panel curtain wall. The junction box is installed on the front of the flexible component. On corrugated steel sheet surfaces: Structural adhesive is fully applied to the back panel of the flexible component, which is then directly adhered to the corrugated steel sheet. The junction box is installed on the back of the flexible component, concealed within the corrugated gaps. On concrete surfaces: A joist is installed on the building surface, and the component is directly adhered to the joist. The junction box is installed on the back of the flexible component, concealed within the joist gaps.

[0085] The use of inorganic polymer reinforcement materials protects the cells, preventing damage even when the cells are bent, making it suitable for curved buildings. It also resists impacts such as hail, ensuring the module's lifespan. While Seraphim's products on the market use a single layer of inorganic polymer reinforcement, this product uses a double layer for better performance. During production, the area of ​​the inorganic polymer reinforcement is smaller than the module size, only needing to exceed the cell size by 2-3mm. This leaves unfilled areas, resulting in a downward slope and unevenness after lamination. Therefore, an adhesive film is used to fill these unfilled areas, ensuring flatness after lamination. The substrate uses semi-tempered glass or fiberglass board to provide flat lamination conditions, ensuring a smooth, pit-free module surface.

[0086] In some embodiments, the solution provided in this application includes: Material configuration: surface weather-resistant polymer material + adhesive film + inorganic polymer reinforcing material + battery cell + inorganic polymer reinforcing material + POE adhesive film + backsheet weather-resistant polymer material. Physicochemical testing methods and results: Weather resistance test (QUV accelerated aging): Testing method: simulated ultraviolet light irradiation (340nm, 0.68W / m²). 2 ) and damp heat cycling (85℃ / 85%RH). Results: The surface of the example showed no yellowing or cracking, and the light transmittance retention was >95%. Mechanical property test (three-point bending): Test method: Apply 50 N / cm 2 Stress was measured, along with flexural strength and elongation at break. Results: Flexural strength ≥120MPa, elongation at break ≥15%. Electrical performance testing (EL+IV curve): Test method: Standard solar simulator (AM1.5G, 1000W / m²). 2 Efficiency was tested. Results: Conversion efficiency 20%, fill factor 82%.

[0087] The provided embodiments are now compared with traditional EVA film solutions and solutions without inorganic reinforcement materials.

[0088] For example, a conventional EVA film solution used for comparison includes: material configuration comprising: surface weather-resistant polymer material + EVA film + glass fiber reinforcement material + solar cell + glass fiber reinforcement material + EVA film + backsheet weather-resistant polymer material. Process parameters: same as provided in the above embodiments. Test results: Weather resistance: transmittance retention rate 88% after QUV testing, with localized yellowing; Mechanical properties: flexural strength 90 MPa, elongation at break 8%; Electrical properties: conversion efficiency 20.2%, filler factor 78%.

[0089] An exemplary inorganic reinforcement material-free solution for comparison includes: Material configuration: surface weather-resistant polymer material + POE film + solar cell + POE film + backsheet. Process parameters: same as the above embodiment. Test results: Weather resistance: transmittance retention rate is 90% after QUV testing, but microcracks appear at the edges; Mechanical properties: flexural strength 100MPa, elongation at break 10%; Electrical properties: conversion efficiency 21.5%, filler factor 79%. Other: solar cells are easily broken after bending, unable to form a curved surface, and do not meet the requirement of a 0.5m bending radius for a 1128*2272 module.

[0090] Surface weather-resistant polymer materials include: Material selection: Fluoropolymers. Basis: Weather resistance: Fluoropolymers have excellent UV resistance (high CF bond energy, resistant to photolysis), allowing for long-term exposure to outdoor environments. Hydrophobicity: The low surface energy design reduces dust adhesion and enhances self-cleaning ability.

[0091] POE film includes: Material: Ethylene-octene copolymer (POE). Basis: Light transmittance: POE light transmittance >92% (EVA is 88%), reducing light loss (data source). Weather resistance: Superior resistance to UV yellowing compared to EVA, and low water vapor transmittance (<0.5g / m²). 2 *day).

[0092] Inorganic polymer reinforcement materials include: Material selection: glass fiber reinforcement. Basis: Mechanical reinforcement: can improve the module's resistance to mechanical stress (bending strength increased by 30%), reducing the risk of cell cracking.

[0093] The weather-resistant polymer material for the backsheet includes: Material selection: PET. Basis: Water vapor barrier: protects the battery cells. Chemical corrosion resistance: resists environmental erosion such as acid rain and salt spray (ASTM B117 salt spray test >1000 hours without corrosion).

[0094] The lamination parameters (the parameters are kept confidential) include: Temperature parameters: the heating temperature of the upper cavity of the first cavity is 85-95℃, the heating temperature of the lower cavity of the first cavity is 115-128℃, the heating temperature of the upper cavity of the second cavity is 85-95℃, and the heating temperature of the lower cavity of the second cavity is 149-159℃. Pressure and time parameters include: Lamination stage 1: vacuuming time 700-730s, first lamination pressure -70KPa~-60KPa, first pressure holding time 10s, second lamination pressure -45KPa~-35KPa, second pressure holding time 10s, third lamination pressure -10KPa~-5KPa, third pressure holding time 100s, lower chamber inflation time 50s; Lamination stage 2: vacuuming time 80-90s, first lamination pressure -70KPa~-60KPa, first pressure holding time 10s, second lamination pressure -45KPa~-35KPa, second pressure holding time 10s, third lamination pressure -10KPa~-5KPa, first pressure holding time 720~750s, lower chamber inflation time 50s; Product qualification indicators include: no bubbles or unmelted adhesive film on the component appearance, complete bonding of all materials, and all parameters meeting national standards and design specifications. The bending radius of the standard size 1128*2272 version can reach 0.5m.

[0095] This invention utilizes a double-layer inorganic polymer reinforcement material symmetrically arranged on the top and bottom sides of the solar cell. Compared to existing single-layer structures, this increases the bending strength to ≥120MPa and the elongation at break to ≥15%, enabling the module to achieve a bending radius of up to 0.5m, meeting the fitting requirements of large-angle curved buildings. Simultaneously, the double-sided support evenly distributes bending stress, preventing cell breakage. By filling the edges not covered by the reinforcement material with an adhesive film, the slope of the module edges after lamination is eliminated. Combined with the flat lamination conditions provided by the substrate (semi-tempered glass / fiberglass board), this ensures a pit-free module surface, improving appearance quality and installation compatibility. Furthermore, the weather-resistant design of the fluorinated surface material and the PET backsheet (resistant to UV yellowing and salt spray corrosion) extends the module's lifespan. Differential temperature control in a dual-chamber laminator (low-temperature preheating in one chamber, high-temperature curing in the second chamber) combined with a segmented pressure process achieves gradient melting of the POE adhesive film and tight adhesion between each layer, reducing bubbles and delamination defects and improving the module's electrical performance stability.

[0096] It should be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. It should be understood that when an element or layer is referred to as “on,” “adjacent to,” “connected to,” or “coupled to” other elements or layers, it may be directly on, adjacent to, connected to, or coupled to other elements or layers, or there may be intervening elements or layers. Conversely, when an element is referred to as “directly on,” “directly adjacent to,” “directly connected to,” or “directly coupled to” other elements or layers, there are no intervening elements or layers. It should be understood that although the terms first, second, third, etc., may be used to describe various elements, components, areas, layers, and / or portions, these elements, components, areas, layers, and / or portions should not be limited by these terms. These terms are merely used to distinguish one element, component, area, layer, or portion from another element, component, area, layer, or portion. Therefore, without departing from the teachings of this application, the first element, component, area, layer, or portion discussed below may be referred to as a second element, component, area, layer, or portion.

[0097] Spatial relation terms such as “below,” “under,” “below,” “under,” “above,” “above,” etc., are used herein for convenience of description to describe the relationship between one element or feature shown in the figure and other elements or features. It should be understood that, in addition to the orientation shown in the figure, spatial relation terms are intended to also include different orientations of the device in use and operation. For example, if the device in the figure is flipped, then the element or feature described as “below,” “under,” or “below” other elements or features will be oriented “above” other elements or features. Therefore, the exemplary terms “below” and “under” can include both above and below orientations. The device may be otherwise oriented (rotated 90 degrees or otherwise) and the spatial descriptive terms used herein will be interpreted accordingly.

[0098] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. When used herein, the singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising” and / or “including,” when used in this specification, identify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups. When used herein, the term “and / or” includes any and all combinations of the associated listed items.

[0099] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0100] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A flexible photovoltaic module BIPV system for curved buildings, characterized in that, It includes, from top to bottom, a surface weather-resistant polymer material, a first layer of adhesive film, a first layer of inorganic polymer reinforcing material, a battery cell, a second layer of inorganic polymer reinforcing material, a second layer of adhesive film, and a backsheet weather-resistant polymer material; The first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material are located on the upper and lower sides of the battery cell, respectively. The area of ​​the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material is smaller than the size of the surface weather-resistant polymer material, the first layer of adhesive film, the battery cell, the second layer of adhesive film and the backsheet weather-resistant polymer material. The unfilled part is filled by the adhesive film. The surface weather-resistant polymer material serves as the outer surface of the flexible module, exhibiting high light transmittance and weather resistance. The backsheet weather-resistant polymer material serves as the module backsheet, possessing weather resistance. The first layer of adhesive film is used to bond the weather-resistant polymer material, the first layer of inorganic polymer reinforcing material, and the solar cells. The second layer of adhesive film is used to bond the solar cells, the second layer of adhesive film, and the backsheet weather-resistant polymer material. Both the first and second layers of adhesive film possess water resistance and weather resistance. The flexible photovoltaic module is laminated using a dual-cavity laminator. The upper heating temperature of the first cavity is 85-95℃, and the lower heating temperature of the first cavity is 115-128℃. The upper heating temperature of the second cavity is 85-95℃, and the lower heating temperature of the second cavity is 149-159℃. The lamination time for the first cavity is 10-13 minutes, and the lamination time for the second cavity is 10-13 minutes.

2. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, During lamination, a high-temperature cloth is first laid on the substrate. The surface weather-resistant polymer material, the first layer of adhesive film, the first layer of inorganic polymer reinforcing material, the battery cell, the second layer of inorganic polymer reinforcing material, the second layer of adhesive film, and the backsheet weather-resistant polymer material are cut and stacked according to standard dimensions and then put into the laminator for lamination. The substrate is made of semi-tempered glass or fiberglass board to provide flat conditions for lamination.

3. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, The edges of the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material extend outward by 2-3 mm relative to the edge of the battery cell, and are smaller than the edge dimensions of the surface weather-resistant polymer material, the first layer of adhesive film, the second layer of adhesive film and the backsheet weather-resistant polymer material, so as to form an unfilled area at the edge of the module.

4. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, By covering and filling the area between the edges of the first layer of inorganic polymer reinforcement material and the second layer of inorganic polymer reinforcement material and the edges of the surface weather-resistant polymer material and the backsheet weather-resistant polymer material with an adhesive film, the slope of the module edges after lamination is eliminated, ensuring the overall flatness of the module.

5. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, The surface weather-resistant polymer material is a fluoropolymer with a light transmittance of not less than 92%, which can resist ultraviolet aging and has a hydrophobic surface to reduce dust adhesion and improve self-cleaning ability.

6. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, The back panel is made of PET, a weather-resistant polymer material that provides water vapor barrier properties and chemical corrosion resistance, enabling it to withstand acid rain and salt spray erosion and meet the requirements for long-term outdoor use; its water vapor permeability is ≤0.5g / m². 2 *day.

7. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, The first and second adhesive layers are POE films with a light transmittance of not less than 92% and a water vapor transmittance of less than 0.5 g / m³. 2 *day achieves high-strength adhesion and long-term weather resistance of each layer of material through molecular structure design.

8. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, A composite reinforcing material is also provided between the surface weather-resistant polymer material and the first layer of inorganic polymer reinforcing material. The first layer of adhesive film is used to sequentially bond the surface weather-resistant polymer material, the composite reinforcing material and the first layer of inorganic polymer reinforcing material. The composite reinforcing material is used to improve the surface smoothness of the component and enhance its impact resistance.

9. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, During the lamination process, the dual-chamber laminator performs segmented pressure control in one chamber: the vacuuming time is 700-730 seconds, followed by a first pressure holding of -70KPa to -60KPa, a second pressure holding of -45KPa to -35KPa, and a third pressure holding of -10KPa to -5KPa; the vacuuming time in the second chamber is 80-90 seconds. Through gradient pressure changes, the adhesive film is melted uniformly and the materials of each layer are tightly bonded, improving the lamination consistency of the components.

10. The flexible photovoltaic module BIPV system according to claim 1, characterized in that, The installation position of the junction box of the flexible photovoltaic module is adjusted according to the adaptability of the installation surface: when on the aluminum panel curtain wall surface, the junction box is installed on the front of the flexible module; when on the corrugated steel tile or concrete surface, the junction box is installed on the back of the flexible module and hidden in the gap of the corrugation or keel, ensuring the aesthetics and safety of the installation structure.

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