Colored film for gaps of photovoltaic modules

Abstract

The invention discloses a color film for gaps of photovoltaic modules, which comprises a reflecting layer, a base material layer, a secondary reflecting layer and a bonding layer, the upper end of the reflecting layer is fixedly connected with the base material layer, the upper end of the base material layer is fixedly connected with the secondary reflecting layer, the upper end of the secondary reflecting layer is fixedly connected with the bonding layer, the reflecting layer faces a battery piece, and the bonding layer is fixedly connected with the bonding layer. The high reflection effect of the coating of the reflecting layer belongs to diffuse reflection and can effectively collect and reflect most light energy for a long time, the base material layer serves as a carrier of the coating and effectively protects the coating, the secondary radiation layer has the high reflection effect and can reflect light energy which cannot be reflected back again and protect a back face structure, and the bonding layer is mainly bonded with a colored gap film. Compared with the prior art, the solar cell module has the advantages that light in gaps of the cell pieces can be reflected into the module, the light utilization rate is improved, the efficiency of the module is improved, and the module is beautified.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module film technology, specifically a colored film for use between photovoltaic modules. Background Technology

[0002] Individual solar cells cannot be used directly as power sources. To function as power sources, several individual cells must be connected in series and parallel and tightly packaged into modules. Photovoltaic modules (also called solar panels) are the core and most important component of a solar power generation system. Their function is to convert solar energy into electrical energy, which is then stored in batteries or used to power loads. However, with the use of micro-inverters, the current source of photovoltaic modules can be directly converted into a voltage source of approximately 40V, enabling the power of electrical appliances in our daily lives. Simultaneously, photovoltaic modules are constantly being innovated, leading to upgraded and innovative products such as photovoltaic ceramic tiles and photovoltaic color steel tiles. These products can directly replace traditional building materials like roof tiles and also possess the functions of photovoltaic modules. Once they enter the general market, they will have a significant impact on both photovoltaic modules and traditional building materials.

[0003] Currently, photovoltaic modules use solar cells connected in series with solder ribbons to form a loop module. Each set of solar cells and each solar string has a gap, and sunlight is lost in these gaps. Our tape is used to fix the solar cells in these gaps using heat bonding or other methods. Different colored reflective materials reflect different wavelengths of light, which not only enhances the aesthetics but also effectively increases the luminous flux of the module. Summary of the Invention

[0004] The technical problem to be solved by this invention is to overcome the above-mentioned technical defects and provide a colored film for the gaps between photovoltaic modules. This invention can reflect the light from the gaps between the cells into the module, thereby improving the light utilization rate, increasing the efficiency of the module, and beautifying the module.

[0005] To solve the above problems, the technical solution of the present invention is as follows: It includes a reflective layer, a substrate layer, a secondary reflective layer, and an adhesive layer. The upper end of the reflective layer is fixedly connected to the substrate layer, the upper end of the substrate layer is fixedly connected to the secondary reflective layer, and the upper end of the secondary reflective layer is fixedly connected to the adhesive layer. The reflective layer faces the battery cell surface. The high reflectivity of the reflective layer coating is diffuse reflection, which can effectively collect and reflect most of the reflected light energy for a long time. The substrate layer serves as a carrier for the coating, effectively protecting the coating. The secondary reflective layer has a high reflectivity, which can reflect the light energy that could not be reflected back, protecting the back structure. The adhesive layer mainly bonds the colored gap film.

[0006] Furthermore, the reflective layer and the secondary reflective layer are fluorine coatings, wherein the fluorine coating is a mixture of a fluorocarbon or fluorine-free resin and a solvent.

[0007] Furthermore, a color masterbatch is added to the fluorine coating resin. The color masterbatch is white, black, or red, etc. The reflective layer and the secondary reflective layer can be selected from different color masterbatches. Antioxidants and anti-aging agents are added to the reflective layer and the secondary reflective layer.

[0008] Furthermore, the adhesive layer is selected from monomers or mixtures of polyolefin elastomers such as POE and EVA, and 0.05-0.2% peroxide is added to the adhesive layer, as well as chemical additives such as crosslinking agents and silane coupling agents.

[0009] Furthermore, the prepared fluorocarbon paint coating must be used within 5 hours to avoid exceeding the activation period and becoming unusable. The fluorocarbon paint should be stored in a dry, waterproof, leak-proof, sun-proof, high-temperature-proof, and fire-free environment. The application temperature should be 0-3 degrees Celsius, and the relative humidity should be less than 80%.

[0010] Furthermore, the POE plastic is a thermoplastic elastomer that is polymerized in situ using metallocene catalysts to polymerize ethylene and octene. The EVA is polymerized by one of the following methods: high-pressure bulk polymerization, solution polymerization, emulsion polymerization, and suspension polymerization. Emulsion polymerization is used when the vinyl acetate (VA) content is higher than 30%, while high-pressure bulk polymerization is used when the vinyl acetate (VA) content is low.

[0011] Furthermore, polyester film is selected as the substrate layer, and the surface is treated with plasma or chemicals to increase the surface tension of the film. The thickness is selected as 25-200 micrometers. A reflective layer and a secondary reflective layer are coated on the surface. According to the needs, a suitable proportion of fluorocarbon or fluorine-free resin and solvent are mixed. A certain proportion of color masterbatch, such as white, black, and red, is added to the resin. The colors of the two layers can be different according to customer needs to increase the aesthetic appearance. A certain proportion of antioxidant and aging agent components are added. The reflective layer and the secondary reflective layer are coated one or simultaneously. The coating solvent is evaporated in a heated oven and cured on the surface of the substrate layer. Then it is rolled up and formed. According to the downstream processing requirements, plasma corona treatment or chemical treatment is used to increase the surface tension of the coating.

[0012] Furthermore, the main materials of the first and second adhesive layers are polyolefin system particles such as EVA, POE, and EAA. Additives such as crosslinking agents, co-crosslinking agents, silane coupling agents, and ultraviolet absorbers are added to the masterbatch, and the addition ratio is between 0.1% and 2% of the mass ratio of the particles of the first and second adhesive layers.

[0013] Furthermore, an adhesive layer is coated onto the surface of the secondary reflective layer. The adhesive layer is selected from monomers or mixtures of polyolefin elastomers such as POE and EVA. Then, a certain proportion of peroxide (0.05-0.2%) and chemical additives such as crosslinking agents and silane coupling agents are added. The preferred processing technology is a low-temperature extrusion process with the temperature controlled at 85-100 degrees Celsius. The coating is applied to the secondary reflective layer with a thickness controlled at 20-100 micrometers. Alternatively, a high-temperature extrusion process can be selected. In high-temperature extrusion, the proportion of peroxide added can be selected or not, and the thickness is also controlled at 20-100 micrometers.

[0014] Furthermore, depending on the usage conditions, after the above layers are applied using various processing methods, irradiation crosslinking can be added. The degree of crosslinking is controlled at 0-50%, which can reduce the risk of the adhesive layer and increase the processing temperature for the client. After the roll material is processed, it is slit into 1-50mm rolls. Depending on the client's battery string design requirements and the needs around the frame, a laminating machine is used.

[0015] The advantages of this invention compared to existing technologies are: this invention can reflect light from the gaps between solar cells into the interior of the module, thereby improving light utilization, increasing module efficiency, and enhancing the aesthetics of the module. Attached Figure Description

[0016] Figure 1 This is a perspective view of a colored film for the gaps between photovoltaic modules according to the present invention.

[0017] As shown in the figure: 1. Reflective layer; 2. Substrate layer; 3. Secondary reflective layer; 4. Adhesive layer. Detailed Implementation

[0018] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals.

[0019] It should be noted that the terms “front,” “back,” “left,” “right,” “up,” and “down” used in the following description refer to the directions shown in the attached diagrams, while the terms “inside” and “outside” refer to the directions toward or away from the geometric center of a specific component, respectively.

[0020] To make the content of this invention easier to understand, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings.

[0021] Example 1

[0022] A colored film for the gaps in photovoltaic modules comprises a reflective layer 1, a substrate layer 2, a secondary reflective layer 3, and an adhesive layer 4. The substrate layer 2 is fixedly connected to the upper end of the reflective layer, the secondary reflective layer 3 is fixedly connected to the upper end of the substrate layer 2, and the adhesive layer 4 is fixedly connected to the upper end of the secondary reflective layer 3. The reflective layer 1 faces the cell surface. The high reflectivity of the coating on the reflective layer 1 results in diffuse reflection, which can effectively collect and reflect most of the reflected light energy over a long period of time. The substrate layer 2 serves as a carrier for the coating, effectively protecting it. The secondary reflective layer 3 has a high reflectivity, which can reflect back any light energy that could not be reflected, protecting the back structure. The adhesive layer 4 mainly bonds the colored gap film.

[0023] Fluorocarbon coatings must be used within 5 hours of preparation to avoid exceeding the activation period and becoming unusable. Fluorocarbon paint should be stored in a dry, waterproof, leak-proof, sun-proof, high-temperature-proof, and fire-free environment. The application temperature should be 0-3 degrees Celsius, and the relative humidity should be less than 80%.

[0024] POE plastic is a thermoplastic elastomer that is polymerized in situ using metallocene catalysts to polymerize ethylene and octene. EVA is polymerized by one of the following methods: high pressure bulk polymerization, solution polymerization, emulsion polymerization, or suspension polymerization. Emulsion polymerization is used when the vinyl acetate (VA) content is higher than 30%, while high pressure bulk polymerization is used when the vinyl acetate (VA) content is low.

[0025] A process for preparing colored films for gaps in photovoltaic modules is as follows: A polyester film is selected as the substrate layer 2. The surface is treated with plasma or chemicals to increase the surface tension of the film. The thickness is selected to be 25 micrometers. A reflective layer 1 and a secondary reflective layer 3 are coated on the surface. A suitable proportion of fluorocarbon or fluorine-free resin and solvent are mixed according to requirements. A certain proportion of color masterbatch (white, black, red, etc.) is added to the resin. The colors of the two layers can be different according to customer needs to enhance the aesthetic appearance. A certain proportion of antioxidants and aging agents are added. The reflective layer 1 and the secondary reflective layer 3 are coated once or simultaneously. The coating solvent is evaporated in a heated oven and cured on the surface of the substrate layer 2. Then, it is rolled up and formed. Depending on the subsequent processing requirements, plasma corona treatment or chemical treatment is used to increase the surface tension of the coating.

[0026] A bonding layer 4 is coated onto the surface of the secondary reflective layer 3. The bonding layer 4 is made of monomers or a mixture of polyolefin elastomers such as POE and EVA. Then, 0.05% peroxide and chemical additives such as crosslinking agents and silane coupling agents are added. The preferred processing technology is low-temperature extrusion, with the temperature controlled at 85 degrees Celsius. The coating is applied to the secondary reflective layer 3 with a thickness controlled at 20 micrometers. Alternatively, a high-temperature extrusion process can be used. In high-temperature extrusion, the peroxide addition ratio can be selected or not, and the thickness is also controlled at 20 micrometers.

[0027] Depending on the usage conditions, after the above layers are applied using various processing methods, irradiation crosslinking can be added. The degree of crosslinking is controlled at 10%, which can reduce the risk of adhesive layer 4 and increase the processing temperature for the client. After the roll material is processed, it is cut into 1mm rolls. Based on the client's battery string design requirements and the needs of the four sides of the frame, a laminating machine is used.

[0028] Example 2

[0029] A colored film for the gaps in photovoltaic modules comprises a reflective layer 1, a substrate layer 2, a secondary reflective layer 3, and an adhesive layer 4. The substrate layer 2 is fixedly connected to the upper end of the reflective layer, the secondary reflective layer 3 is fixedly connected to the upper end of the substrate layer 2, and the adhesive layer 4 is fixedly connected to the upper end of the secondary reflective layer 3. The reflective layer 1 faces the cell surface. The high reflectivity of the coating on the reflective layer 1 results in diffuse reflection, which can effectively collect and reflect most of the reflected light energy over a long period of time. The substrate layer 2 serves as a carrier for the coating, effectively protecting it. The secondary reflective layer 3 has a high reflectivity, which can reflect back any light energy that could not be reflected, protecting the back structure. The adhesive layer 4 mainly bonds the colored gap film.

[0030] Fluorocarbon coatings must be used within 5 hours of preparation to avoid exceeding the activation period and becoming unusable. Fluorocarbon paint should be stored in a dry, waterproof, leak-proof, sun-proof, high-temperature-proof, and fire-free environment. The application temperature should be 0-3 degrees Celsius, and the relative humidity should be less than 80%.

[0031] POE plastic is a thermoplastic elastomer that is polymerized in situ using metallocene catalysts to polymerize ethylene and octene. EVA is polymerized by one of the following methods: high pressure bulk polymerization, solution polymerization, emulsion polymerization, or suspension polymerization. Emulsion polymerization is used when the vinyl acetate (VA) content is higher than 30%, while high pressure bulk polymerization is used when the vinyl acetate (VA) content is low.

[0032] A process for preparing colored films for gaps in photovoltaic modules is as follows: A polyester film is selected as the substrate layer 2. The surface is treated with plasma or chemicals to increase the surface tension of the film. The thickness is selected to be 85 micrometers. A reflective layer 1 and a secondary reflective layer 3 are coated on the surface. A suitable proportion of fluorocarbon or fluorine-free resin and solvent are mixed according to requirements. A certain proportion of color masterbatch (white, black, red, etc.) is added to the resin. The colors of the two layers can be different according to customer needs to enhance the aesthetic appearance. A certain proportion of antioxidants and aging agents are added. The reflective layer 1 and the secondary reflective layer 3 are coated once or simultaneously. The solvent in the coating layer is evaporated in a heated oven and cured on the surface of the substrate layer 2. Then, it is rolled up and formed. Depending on the subsequent processing requirements, plasma corona treatment or chemical treatment is used to increase the surface tension of the coating.

[0033] A bonding layer 4 is coated onto the surface of the secondary reflective layer 3. The bonding layer 4 is made of monomers or mixtures of polyolefin elastomers such as POE and EVA. A certain proportion of peroxide (0.12%) and chemical additives such as crosslinking agents and silane coupling agents are added. The preferred processing technology is low-temperature extrusion, with the temperature controlled at 92 degrees Celsius. The coating is applied to the secondary reflective layer 3 with a thickness controlled at 60 micrometers. Alternatively, a high-temperature extrusion process can be used, in which the peroxide addition ratio can be selected or not, and the thickness is also controlled at 60 micrometers.

[0034] Depending on the usage conditions, after the above layers are applied using various processing methods, irradiation crosslinking can be added. The degree of crosslinking is controlled at 25%, which can reduce the risk of adhesive layer 4 and increase the processing temperature for the client. After the roll material is processed, it is cut into 25mm rolls. Based on the client's battery string design requirements and the needs of the surrounding edges, a laminating machine is used.

[0035] Example 3

[0036] A colored film for the gaps in photovoltaic modules comprises a reflective layer 1, a substrate layer 2, a secondary reflective layer 3, and an adhesive layer 4. The substrate layer 2 is fixedly connected to the upper end of the reflective layer, the secondary reflective layer 3 is fixedly connected to the upper end of the substrate layer 2, and the adhesive layer 4 is fixedly connected to the upper end of the secondary reflective layer 3. The reflective layer 1 faces the cell surface. The high reflectivity of the coating on the reflective layer 1 results in diffuse reflection, which can effectively collect and reflect most of the reflected light energy over a long period of time. The substrate layer 2 serves as a carrier for the coating, effectively protecting it. The secondary reflective layer 3 has a high reflectivity, which can reflect back any light energy that could not be reflected, protecting the back structure. The adhesive layer 4 mainly bonds the colored gap film.

[0037] Fluorocarbon coatings must be used within 5 hours of preparation to avoid exceeding the activation period and becoming unusable. Fluorocarbon paint should be stored in a dry, waterproof, leak-proof, sun-proof, high-temperature-proof, and fire-free environment. The application temperature should be 0-3 degrees Celsius, and the relative humidity should be less than 80%.

[0038] POE plastic is a thermoplastic elastomer that is polymerized in situ using metallocene catalysts to polymerize ethylene and octene. EVA is polymerized by one of the following methods: high pressure bulk polymerization, solution polymerization, emulsion polymerization, or suspension polymerization. Emulsion polymerization is used when the vinyl acetate (VA) content is higher than 30%, while high pressure bulk polymerization is used when the vinyl acetate (VA) content is low.

[0039] A process for preparing colored films for gaps in photovoltaic modules is as follows: A polyester film is selected as the substrate layer 2. The surface is treated with plasma or chemicals to increase the surface tension of the film. The thickness is selected to be 200 micrometers. A reflective layer 1 and a secondary reflective layer 3 are coated on the surface. A suitable proportion of fluorocarbon or fluorine-free resin and solvent are mixed according to requirements. A certain proportion of color masterbatch (white, black, red, etc.) is added to the resin. The colors of the two layers can be different according to customer needs to enhance the aesthetic appearance. A certain proportion of antioxidants and aging agents are added. The reflective layer 1 and the secondary reflective layer 3 are coated once or simultaneously. The coating solvent is evaporated in a heated oven and cured on the surface of the substrate layer 2. Then, it is rolled up and formed. Depending on the subsequent processing requirements, plasma corona treatment or chemical treatment is used to increase the surface tension of the coating.

[0040] A bonding layer 4 is coated onto the surface of the secondary reflective layer 3. The bonding layer 4 is made of monomers or a mixture of polyolefin elastomers such as POE and EVA. A certain proportion of peroxide (0.2%) and chemical additives such as crosslinking agents and silane coupling agents are added. The preferred processing technology is low-temperature extrusion, with the temperature controlled at 100 degrees Celsius. The coating is applied to the secondary reflective layer 3 with a thickness controlled at 100 micrometers. Alternatively, a high-temperature extrusion process can be used, in which the peroxide addition ratio can be selected or not, and the thickness is also controlled at 100 micrometers.

[0041] Depending on the usage conditions, after the above layers are applied using various processing methods, irradiation crosslinking can be added. The degree of crosslinking is controlled at 40%, which can reduce the risk of adhesive layer 4 and increase the processing temperature for the client. After the roll material is processed, it is cut into 50mm rolls. Based on the client's battery string design requirements and the needs of the surrounding frame, a laminating machine is used.

[0042] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A colored film for use in the gaps between photovoltaic modules, characterized in that: The structure includes a reflective layer (1), a substrate layer (2), a secondary reflective layer (3), and an adhesive layer (4). The upper end of the reflective layer is fixedly connected to the substrate layer (2), the upper end of the substrate layer (2) is fixedly connected to the secondary reflective layer (3), and the upper end of the secondary reflective layer (3) is fixedly connected to the adhesive layer (4). The reflective layer (1) faces the battery cell surface. The high reflectivity of the coating on the reflective layer (1) is diffuse reflection, which can effectively collect and reflect most of the light energy for a long time. The substrate layer (2) serves as a carrier for the coating and effectively protects the coating. The secondary reflective layer (3) has a high reflectivity and can reflect the light energy that could not be reflected back, protecting the back structure. The adhesive layer (4) mainly bonds the colored gap film.

2. The colored film for the gaps between photovoltaic modules according to claim 1, characterized in that: The reflective layer (1) and the secondary reflective layer (3) are fluorine coatings, which are a mixture of fluorocarbon or fluorine-free resin and a solvent.

3. A colored film for the gaps between photovoltaic modules according to claim 2, characterized in that: A color masterbatch is added to the fluorine coating resin. The color masterbatch is white, black, or red, etc. The reflective layer (1) and the secondary reflective layer (3) can be selected from different color masterbatches. Antioxidants and anti-aging agents are added to the reflective layer (1) and the secondary reflective layer (3).

4. A colored film for the gaps between photovoltaic modules according to claim 1, characterized in that: The adhesive layer (4) is selected from monomers of polyolefin elastomers such as POE and EVA or a mixture of multiple types. 0.05-0.2% of peroxide is added to the adhesive layer (4). Chemical additives such as crosslinking agents and silane coupling agents are added to the adhesive layer (4).

5. A colored film for the gaps between photovoltaic modules according to claim 1, characterized in that: The prepared fluorocarbon paint coating must be used within 5 hours to avoid exceeding the activation period and becoming unusable. The fluorocarbon paint should be stored in a dry, waterproof, leak-proof, sun-proof, high-temperature-proof, and fire-free environment. The application temperature should be 0-3 degrees Celsius, and the relative humidity should be less than 80%.

6. A colored film for the gaps between photovoltaic modules according to claim 1, characterized in that: The POE plastic is a thermoplastic elastomer that is polymerized in situ using metallocene catalysts to polymerize ethylene and octene. The EVA is polymerized by one of the following methods: high-pressure bulk polymerization, solution polymerization, emulsion polymerization, and suspension polymerization. Emulsion polymerization is used when the vinyl acetate (VA) content is higher than 30%, while high-pressure bulk polymerization is used when the vinyl acetate (VA) content is low.

7. The process for preparing a colored film for the gap between photovoltaic modules according to claim 1, characterized in that: Polyester film is selected as the substrate layer (2). The surface is plasma-treated or chemically treated to increase the surface tension of the film. The thickness is selected as 25-200 micrometers. A reflective layer (1) and a secondary reflective layer (3) are coated on the surface. According to your needs, a suitable proportion of fluorocarbon or fluorine-free resin and solvent are mixed. A certain proportion of color masterbatch is added to the resin, such as white, black, red, etc. The colors of the two layers can be different according to the customer's needs to increase the aesthetic appearance. A certain proportion of antioxidant and aging agent components are added. The reflective layer (1) and the secondary reflective layer (3) are coated once or simultaneously. The coating solvent is evaporated in a heating oven and cured on the surface of the substrate layer (2). Then it is rolled up and formed. According to the downstream processing requirements, plasma corona treatment or chemical treatment is used to increase the surface tension of the coating.

8. The process for preparing a colored film for the gap between photovoltaic modules according to claim 1, characterized in that: The adhesive layer (4) is coated on the surface of the secondary reflective layer (3). The adhesive layer (4) is selected from monomers or mixtures of polyolefin elastomers such as POE and EVA. Then, a certain proportion of peroxide 0.05-0.2% and chemical additives such as crosslinking agent and silane coupling agent are added. The preferred processing technology is low temperature extrusion process, with the temperature controlled at 85-100 degrees Celsius. The coating is applied to the secondary reflective layer (3) with a thickness controlled at 20-100 micrometers. Alternatively, a high temperature extrusion process can be selected. In high temperature extrusion, the peroxide addition ratio can be selected or not, and the thickness is also controlled at 20-100 micrometers.

9. The process for preparing a colored film for the gap between photovoltaic modules according to claim 1, characterized in that: Depending on the usage conditions, after the above layers are made by various processing methods, irradiation crosslinking can be added. The degree of crosslinking is controlled at 0-50%, which can reduce the risk of the adhesive layer (4) and increase the processing temperature of the client. After the roll material is processed, it is cut into 1-50mm rolls. The client's battery string design requirements and the needs of the frame are met by using a film applicator.

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