Colored photovoltaic module for vehicles and method of manufacture

Abstract

The application provides a vehicle color photovoltaic module and a preparation method, and relates to the technical field of vehicle-mounted photovoltaic technology. The vehicle color photovoltaic module comprises a curved glass panel, a curved encapsulating back plate arranged opposite to the curved glass panel, a color light film layer arranged between the curved glass panel and the curved encapsulating back plate, a light-transmitting base film layer and a color coating layer arranged on the light-transmitting base film layer, the color coating layer is composed of at least two layers of inorganic material layers with different refractive indexes, the refractive indexes of adjacent two layers of inorganic materials are different, the color coating layer selectively reflects incident light through optical interference between the inorganic material layers to present structural color, and a curved cell layer is arranged between the color light film layer and the curved encapsulating back plate. The color light film layer generates structural color through optical interference of inorganic material layers, avoids discoloration and aging of organic pigments or dyes under long-term sunlight, and has high color stability.

Description

Technical Field

[0001] This application relates to the field of automotive photovoltaic technology, and more specifically, to a color photovoltaic module for vehicles and its preparation method. Background Technology

[0002] Currently, most automotive photovoltaic (PV) modules are planar structures, making it difficult to perfectly integrate with the curved surfaces of car bodies and roofs. This not only affects aesthetics but also limits the vehicle's integration design. Furthermore, traditional colored PV modules typically use pigments or dyes for coloring. These organic materials are prone to fading and aging during long-term outdoor use and can absorb some incident light, reducing PV conversion efficiency. In addition, existing colored PV modules are mostly designed for planar lamination processes, which cannot meet the comprehensive requirements of optical consistency, color durability, and structural compatibility for curved automotive applications.

[0003] Therefore, designing a color photovoltaic module for automobiles that can adapt to curved car bodies, has stable color, and has minimal efficiency loss has become a pressing technical problem that needs to be solved. Summary of the Invention

[0004] This application aims to at least address the problems of color instability and low photoelectric conversion efficiency in automotive colored photovoltaic modules in related technologies.

[0005] In view of this, the first aspect of this application proposes a color photovoltaic module for automobiles, comprising: a curved glass panel; a curved encapsulation backplate disposed opposite to the curved glass panel; a color light film layer disposed between the curved glass panel and the curved encapsulation backplate, the color light film layer comprising a light-transmitting base film layer and a color coating layer disposed on the light-transmitting base film layer, the color coating layer being composed of at least two layers of inorganic materials with different refractive indices stacked together, and the refractive indices of adjacent inorganic materials being different, the color coating layer selectively reflecting incident light through optical interference between the inorganic material layers to present structural colors; and a curved battery layer disposed between the color light film layer and the curved encapsulation backplate; wherein the curved glass panel, the color light film layer, the curved battery layer, and the curved encapsulation backplate are stacked sequentially, and the curved shape of the laminated color light film layer, the curved battery layer, and the curved encapsulation backplate matches the shape of the curved glass panel.

[0006] The automotive-grade colored photovoltaic module provided in this application includes a curved glass panel, a curved encapsulation backplane, a colored light film layer, and a curved cell layer. The curved glass panel, as the outermost layer of the module, transmits incident light and provides mechanical support and physical protection. The curved encapsulation backplane is positioned opposite the curved glass panel and seals the back of the module to prevent moisture and impurities from entering. The colored light film layer is disposed between the curved glass panel and the curved encapsulation backplane. The colored light film layer includes a light-transmitting base film layer and a colored coating layer disposed on the light-transmitting base film layer. The light-transmitting base film layer is a polymer film used to support the colored coating layer and allow light to pass through. The colored coating layer is composed of at least two layers of inorganic materials with different refractive indices, with adjacent inorganic materials having different refractive indices. The colored coating layer utilizes optical interference between the inorganic material layers to selectively reflect incident light, thereby presenting structural color. Structural color refers to the color produced by the interference, diffraction, or scattering of incident light by the microstructure of an object's surface, distinguished from chemical color produced by chemical dyes or pigments absorbing specific wavelengths. A curved battery layer is positioned between the colored light film layer and the curved encapsulation backplate to convert a portion of the incident light transmitted through the colored light film layer into electrical energy. The curved glass panel, colored light film layer, curved battery layer, and curved encapsulation backplate are stacked sequentially. After lamination, the curved shapes of the colored light film layer, curved battery layer, and curved encapsulation backplate match the shape of the curved glass panel.

[0007] When automotive colored photovoltaic modules are operating, sunlight first passes through the curved glass panel to reach the colored light film layer. The colored coating layer reflects specific wavelengths of light through optical interference, while the remaining wavelengths continue to pass through the transparent base film layer and enter the curved cell layer. The curved cell layer absorbs this light energy and generates a photocurrent. The curved structure design of the automotive colored photovoltaic modules allows the entire module to be integrated into curved body parts such as the roof and hood, without compromising the aesthetics of the vehicle's overall design. The colored light film layer uses optical interference of inorganic material layers to generate structural colors, avoiding the fading and aging of organic pigments or dyes under long-term sunlight exposure, resulting in high color stability. The light reflected by the structural colors does not participate in power generation, but the reflected wavelength can be precisely designed, minimizing its impact on the remaining transmitted light, thus maintaining a high photoelectric conversion efficiency for the curved cell layer.

[0008] Optionally, the automotive-grade colored photovoltaic module further includes: a first encapsulating film layer connecting the curved glass panel and the colored light film layer; a second encapsulating film layer connecting the colored light film layer and the curved cell layer; and a third encapsulating film layer connecting the curved cell layer and the curved encapsulation backplane. That is, the first encapsulating film layer connects the curved glass panel and the colored light film layer, the second encapsulating film layer connects the colored light film layer and the curved cell layer, and the third encapsulating film layer connects the curved cell layer and the curved encapsulation backplane. During the lamination process, the multiple encapsulating film layers fill the curved gaps between the layers, ensuring the bonding strength and optical transparency between the layers, ultimately resulting in an automotive-grade colored photovoltaic module with good weather resistance, long-lasting color, and excellent power generation performance.

[0009] Optionally, in some embodiments, the surface of the light-transmitting base film layer is provided with a nano-imprinted grating, the light-transmitting base film layer is a polyethylene terephthalate film or a polyamide film, and the thickness is greater than or equal to 15 μm and less than or equal to 25 μm; the total number of color coating layers is an odd number of layers, and the thickness of each layer in the color coating layer is different and distributed in a non-arithmetic or non-geometric sequence.

[0010] Thus, a nanoimprint grating is formed on the surface of the transparent base film layer. The nanoimprint grating is a periodic micro / nano structure formed on the surface of the transparent base film layer through a nanoimprinting process. It is used to diffract or scatter incident light, thereby assisting or modulating the structural color presented by the colored coating layer. The transparent base film layer is made of polyethylene terephthalate or polyamide film, and its thickness is greater than or equal to 15 μm and less than or equal to 25 μm. This thickness range ensures both the mechanical strength and dimensional stability of the transparent base film layer, and allows it to adapt to changes in surface shape during lamination without cracking or wrinkling. The colored coating layer consists of at least two layers of inorganic materials with different refractive indices stacked together, and the total number of layers in the colored coating layer is odd. The odd-numbered layer structure ensures that the outermost and innermost layers of the colored coating layer have the same or similar optical boundary conditions, which is beneficial for improving the contrast of optical interference and making the reflected colors more saturated and pure. Meanwhile, the thicknesses of the inorganic material layers in the colored coating are varying, and the thicknesses of each layer exhibit a non-arithmetic or non-geometric distribution. This non-arithmetic or non-geometric thickness distribution avoids periodic thickness variations, thereby broadening the reflection spectrum or forming a specific color response curve. It also suppresses secondary interference peaks caused by regular thickness variations, resulting in higher color purity and angular stability in the final structural color. In other words, the nanoimprinted grating on the surface of the transparent base film layer produces a weak diffraction effect on the incident light, dispersing some of the light to different angles. Combined with the multi-beam interference effect of the colored coating layer, this ensures that the color of the reflected light maintains minimal change or exhibits the desired gradient effect at different viewing angles. Therefore, the synergistic effect of nanoimprint gratings and colored coating layers can expand the color gamut of structural colors and improve the color shift problem at large angles, so that the color photovoltaic modules of automobiles can have consistent color performance in different parts of the curved surface of the vehicle body. Moreover, the color photovoltaic modules of automobiles can present a stable, rich and weather-resistant color appearance while maintaining high photoelectric conversion efficiency, meeting the requirements of automobile manufacturing for color quality and reliability.

[0011] Optionally, in some embodiments, the inorganic material includes at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride, the total number of layers of the color coating layer is greater than or equal to 3, and the thickness of each layer of the color coating layer is greater than or equal to 50 nm and less than or equal to 210 nm.

[0012] Thus, the colored coating layer is composed of at least two inorganic materials stacked together, including at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. Silicon dioxide has a low refractive index, titanium dioxide has a high refractive index, aluminum-doped zinc oxide has both conductivity and a medium refractive index, and silicon nitride has a high refractive index and good density. The inorganic materials selected in this application all possess high hardness, high weather resistance, and low light absorption, ensuring that the colored coating layer does not fade or decompose under long-term ultraviolet irradiation and temperature cycling, and that a strong multi-beam interference effect is generated at the interfaces between layers. A total of three or more layers enhances the contrast of the interference effect, producing purer colors compared to a two-layer structure. The thickness of each layer is controlled between 50 nm and 210 nm, avoiding discontinuities or pinhole defects caused by excessive thinness, and avoiding unnecessary film stress or color shift caused by excessive thickness. Meanwhile, the thickness range of each layer is compatible with the curved lamination process, maintaining the stability of the film structure under the lamination temperature and pressure of curved glass panels and curved encapsulation backplanes, thereby providing a durable, uniform and customizable color appearance for automotive colored photovoltaic modules.

[0013] Optionally, in some embodiments, the total number of color coating layers is 7 layers, the thickness of each layer of the color coating layer is greater than or equal to 50 nm and less than or equal to 200 nm, and the total thickness is greater than or equal to 400 nm and less than or equal to 1300 nm.

[0014] Thus, the total number of colored coating layers is seven, ensuring that the outermost and innermost layers have the same optical boundary conditions, which is beneficial for forming a high-contrast interference spectrum. Simultaneously, the seven layers provide a sufficient number of interference optical paths, resulting in a high peak reflectance of the reflection spectrum. The thickness of each layer of the colored coating is independently selected within the range of 50nm to 200nm, and the total thickness is controlled between 400nm and 1300nm, allowing the center wavelength of the reflection peak to be precisely located in the blue, green, red, or intermediate color regions of the visible spectrum. Unreflected light of other wavelengths passes through the colored coating layers into the curved solar cell layer, which converts the transmitted light into electrical energy. Therefore, the automotive colored photovoltaic module of this application provides precisely controllable structural color while maintaining high incident light utilization.

[0015] Optionally, in some embodiments, the thickness of the curved glass panel is greater than or equal to 2 mm and less than or equal to 3.5 mm, the radius of curvature is greater than or equal to 2.5 m and less than or equal to 3.5 m, and the vertical distance from the edge of the curved glass panel to the highest point is greater than or equal to 0.2 m and less than or equal to 0.3 m.

[0016] Thus, the thickness of the curved glass panel is greater than or equal to 2mm and less than or equal to 3.5mm. This thickness range provides sufficient impact resistance while maintaining appropriate light transmittance to allow sunlight to enter the interior of the automotive colored photovoltaic modules. The radius of curvature of the curved glass panel is greater than or equal to 2.5m and less than or equal to 3.5m, and the vertical distance from the edge of the curved glass panel to its highest point is greater than or equal to 0.2m and less than or equal to 0.3m. The curvature parameters match the shape of the car roof or hood, allowing the automotive colored photovoltaic modules to be installed on the vehicle body surface and form a continuous appearance profile with the surrounding sheet metal. Therefore, the thickness of the curved glass panel, between 2mm and 3.5mm, balances lightweight design and structural strength. The limitations on the radius of curvature and arch height result in a high yield rate for hot bending of the glass and compatibility with existing automotive glass shapes. The matching curved shape reduces the negative impact of the automotive colored photovoltaic modules on the vehicle's aerodynamics and also facilitates the sliding off of rainwater and dirt. Automotive color photovoltaic modules can be reliably installed on the curved surfaces of the vehicle body, providing long-lasting color power generation without compromising the overall aesthetic design of the vehicle.

[0017] Optionally, in some embodiments, the curved encapsulation backplane is made of a light-transmitting polymer material, including any one of transparent CPC (Copolyester), transparent PET (Polyethylene Terephthalate), transparent PC (Polycarbonate), or transparent PMMA (Polymethyl Methacrylate); the thickness of the curved encapsulation backplane is greater than or equal to 0.3 mm and less than or equal to 0.4 mm.

[0018] Therefore, the curved encapsulation backsheet is made of a light-transmitting polymer material, including any one of transparent CPC, transparent PET, transparent PC, or transparent PMMA. The thickness of the curved encapsulation backsheet is greater than or equal to 0.3 mm and less than or equal to 0.4 mm. This thickness range allows the curved encapsulation backsheet to maintain sufficient moisture barrier and electrical insulation performance while possessing sufficient flexibility to adapt to the curved lamination process. The curved encapsulation backsheet is positioned opposite the curved glass panel to seal the back of the automotive color photovoltaic module, preventing moisture, oxygen, and dust from penetrating the curved battery layer from the back. Therefore, using a curved encapsulation backsheet made of transparent CPC, transparent PET, transparent PC, or transparent PMMA, with a thickness controlled between 0.3 mm and 0.4 mm, reduces the overall weight of the automotive color photovoltaic module while ensuring sufficient mechanical support and insulation protection. The light-transmitting properties allow automotive color photovoltaic modules to be made in semi-transparent or bi-sided power generation forms, suitable for installation in areas requiring light transmission, such as sunroofs or rear windows of automobiles. Meanwhile, the polymer material at the aforementioned thickness has excellent thermoforming capabilities, enabling it to maintain the same curvature as the curved glass panel, thus avoiding springback or delamination after lamination. This ensures the reliability and appearance consistency of automotive color photovoltaic modules under long-term vehicle vibration and temperature change environments.

[0019] Optionally, in some embodiments, the curved battery layer includes a crystalline silicon battery string layer, which includes at least one of a full back contact battery, a tunnel oxide passivated contact battery, or a heterojunction battery.

[0020] Thus, the curved solar cell layer includes crystalline silicon cell string layers. A crystalline silicon cell string layer consists of multiple crystalline silicon cells connected in series or parallel via conductive connectors, used to convert light energy into electrical energy. The crystalline silicon cell string layer includes at least one of full-back contact cells, tunneling oxide passivated contact cells, or heterojunction cells. Using full-back contact cells avoids the front grid lines blocking light, allowing more light to enter the effective area of ​​the cell, thereby improving the conversion efficiency of automotive color photovoltaic modules. Using tunneling oxide passivated contact cells reduces the back recombination rate, making them suitable for bi-sided or low-light environments. Using heterojunction cells maintains high power output at high temperatures, making them suitable for installation on vehicle roofs and other locations where they heat up quickly under sunlight. The curved adaptability of the crystalline silicon cell string layers in the curved solar cell layer allows automotive color photovoltaic modules to closely conform to the vehicle's contours while maintaining high photoelectric conversion performance.

[0021] Optionally, in some embodiments, the crystalline silicon cell string layer includes multiple half-cells, which are arranged sequentially along a direction perpendicular to the thickness, and adjacent half-cells are connected in series by solder strips to form the crystalline silicon cell string layer.

[0022] Thus, the crystalline silicon solar cell string layer comprises multiple half-cells. A half-cell is a cell unit formed by cutting a standard-sized crystalline silicon solar cell in half along its length. The area of ​​each half-cell is approximately half that of the original cell, resulting in a correspondingly lower operating current. Multiple half-cells are arranged sequentially along a direction perpendicular to the thickness of the curved solar cell layer, i.e., multiple half-cells are arranged sequentially in the planar direction of the curved solar cell layer. Adjacent half-cells are connected in series via solder ribbons to form a cell string. The solder ribbons are copper strips coated with low-melting-point solder. During soldering, the melted solder connects the front electrode of one half-cell to the back electrode of the adjacent half-cell, achieving electrical series connection. After multiple half-cells are connected in series, positive and negative electrodes are led out from both ends of the cell string to collect current. Therefore, this application uses half-cells instead of whole cells, reducing the operating current of each cell unit, thereby reducing resistive heat loss on the solder ribbons and electrodes, and improving the output power of automotive color photovoltaic modules. Multiple half-cells are arranged sequentially along the curved surface and connected in series by solder strips, giving the curved cell layer excellent flexibility and adaptability. This allows it to fit tightly against the curved surface of the glass panel without the cells breaking. The soldered connection method ensures the electrical reliability of the crystalline silicon cell string layer; even in the vibration environment of a vehicle, the solder joints will not loosen, improving the long-term stability of automotive color photovoltaic modules.

[0023] Optionally, the first film layer includes one of POE (Polyolefin Elastomer), EVA (Ethylene-Vinyl Acetate Copolymer), or EPE (EVA-POE-EVA, Ethylene-Vinyl Acetate Copolymer and Polyolefin Elastomer) film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm; and / or the second film layer includes one of POE film, EVA film, or EPE film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm; and / or the third film layer includes one of POE film, EVA film, or EPE film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm.

[0024] Thus, the first adhesive film layer connects the curved glass panel and the colored light film layer. The first adhesive film layer includes one of POE film, EVA film, or EPE film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm. POE film is a polyolefin elastomer film with low water vapor transmission and high volume resistivity. EVA film is an ethylene-vinyl acetate copolymer film with good flowability and adhesion. EPE film is a co-extruded composite film of EVA and POE, combining some of the advantages of both. The first, second, and third adhesive film layers can be made of the same material to simplify the process, or different materials can be selected according to their respective positions to optimize performance. For example, the first adhesive film layer can be made of high-transmittance EVA, the second adhesive film layer can be made of anti-aging POE, and the third adhesive film layer can be made of EPE, which has both adhesive and water-blocking properties. During the curved lamination process, the three layers of adhesive film melt and solidify simultaneously, pressing the curved glass panel, colored light film layer, curved battery layer and curved encapsulation backplate into a whole, and matching the curved shapes of each layer. This ensures the reliability of interlayer bonding and long-term weather resistance of the automotive colored photovoltaic module in the curved shape.

[0025] Based on the same technical concept, the second aspect of this application proposes a method for preparing a color photovoltaic module for automobiles, used to prepare the color photovoltaic module for automobiles as proposed in the first aspect. The method for preparing the color photovoltaic module for automobiles includes: depositing an inorganic material layer on a light-transmitting base film layer using magnetron sputtering; depositing another inorganic material layer on the deposited inorganic material layer using magnetron sputtering, wherein the refractive indices of adjacent inorganic material layers are different; and continuing to deposit new inorganic material layers using magnetron sputtering until a color coating layer that meets the preset requirements is formed, which is light-transmitting. A base film layer and a colored coating layer together form a colored light film layer; a curved glass panel, a colored light film layer, a curved battery layer, and a curved encapsulation backplane are sequentially stacked to form a laminated structure; the laminated structure is placed on a mold that matches the shape of the curved glass panel; the mold containing the laminated structure is placed in a vacuum bag, and the vacuum bag is evacuated; lamination is performed under vacuum to bond and cure the layers, resulting in a colored photovoltaic module for automotive applications; the parameters of the magnetron sputtering method include a power density of ≥3W / cm². 2 And less than or equal to 10W / cm 2 The target evaporation rate is greater than or equal to 50 nm / h and less than or equal to 100 nm / h. The vacuum degree of the vacuum treatment is controlled between -25 kPa and -10 kPa. The lamination temperature is greater than or equal to 140℃ and less than or equal to 150℃. The lamination time is greater than or equal to 35 min and less than or equal to 50 min.

[0026] According to the fabrication method of the automotive color photovoltaic module provided in this application, firstly, an inorganic material layer is deposited on a transparent substrate layer using magnetron sputtering. Then, another inorganic material layer is deposited on top of the previously deposited inorganic material layer using magnetron sputtering, with adjacent inorganic material layers having different refractive indices. The power density of the magnetron sputtering is greater than or equal to 3 W / cm². 2 And less than or equal to 10W / cm 2 This method ensures effective sputtering of target atoms while avoiding excessive power that could lead to a porous film structure or overheating and deformation of the substrate. The target evaporation rate is greater than or equal to 50 nm / h and less than or equal to 100 nm / h, resulting in a dense and uniform thin film and reducing pinholes and stress defects. New inorganic material layers are then deposited using magnetron sputtering, following a predetermined layer-by-layer sequence until a colored coating layer meeting the predefined requirements is formed. The colored coating layer consists of at least two layers of inorganic materials with different refractive indices stacked together. The incident light is selectively reflected through optical interference between the inorganic material layers to reveal the structural color.

[0027] After the colored light film layer is prepared, the curved glass panel, the first encapsulating film layer, the colored light film layer, the second encapsulating film layer, the curved battery layer, the third encapsulating film layer, and the curved encapsulation backplate are sequentially stacked to form a laminated structure. The laminated structure is then placed on a mold that matches the shape of the curved glass panel. The curved shape of the mold matches the curved shape of the glass panel, serving to support and maintain the curved shape of the laminated structure in subsequent processes. The mold containing the laminated structure is placed in a vacuum bag, and the vacuum bag is then evacuated. The vacuum level is controlled between -25 kPa and -10 kPa to effectively remove air bubbles from the laminated structure without causing excessive pressure that could crush the curved glass panel or cause microcracks in the battery cells. Lamination is then performed under vacuum conditions at a temperature greater than or equal to 140°C and less than or equal to 150°C for a lamination time greater than or equal to 35 minutes and less than or equal to 50 minutes. During this process, the first, second, and third adhesive film layers melt under heat and flow under vacuum pressure, filling the curved gaps between the layers. Simultaneously, this presses together the curved glass panel, the colored light film layer, the curved battery layer, and the curved encapsulation backplate. After lamination, the adhesive film layers cool and solidify, bonding each layer into a single unit, resulting in a color photovoltaic module for automobiles. The entire manufacturing method is adapted to the specific radius of curvature and arch height of the curved glass panel. The mold and vacuum bag ensure that the curved shapes of the colored light film layer, the curved battery layer, and the curved encapsulation backplate match the shape of the curved glass panel after lamination, thus enabling mass production of color photovoltaic modules for automobiles with stable color, reliable interlayer bonding, and adaptability to the curved surfaces of the vehicle body.

[0028] Optionally, in some embodiments, the inorganic material includes at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. The preset requirements include that the total number of layers of the color coating is an odd number and greater than or equal to 3 layers, and that the thickness of each layer of the color coating is greater than or equal to 50 nm and less than or equal to 210 nm.

[0029] Thus, the inorganic materials deposited by magnetron sputtering include at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. Prerequisites include an odd number of layers and at least three layers in total for the colored coating, and each layer's thickness being at least 50 nm and less than or equal to 210 nm. Alternating deposition of at least two inorganic materials with significantly different refractive indices creates a strong multi-beam interference effect, resulting in highly saturated and bright structural colors. Using an odd number of layers and at least three layers ensures that the outermost and innermost layers of the colored coating are under similar optical boundary conditions, effectively improving the contrast of the interference spectrum and preventing the reflected colors from becoming dark or whitish. Simultaneously, the color of the automotive-grade colored photovoltaic modules will not fade under long-term exposure to outdoor sunlight and temperature changes, while maintaining high light transmittance and avoiding significant loss of power generation efficiency in the curved battery layer. Attached Figure Description

[0030] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0031] Figure 1 This invention illustrates one of the structural schematic diagrams of a vehicle-mounted color photovoltaic module according to one embodiment of the present application;

[0032] Figure 2 A schematic diagram of the structure of the light-transmitting base film layer in one embodiment of this application is shown;

[0033] Figure 3 This is shown as a second schematic diagram of the structure of a vehicle-mounted color photovoltaic module according to one embodiment of this application;

[0034] Figure 4 This paper shows a schematic diagram of the structure of a crystalline silicon cell string layer in one embodiment of this application;

[0035] Figure 5 A flowchart illustrating a method for preparing a color photovoltaic module for vehicles according to one embodiment of this application is shown.

[0036] Among them: 100 automotive colored photovoltaic modules, 1 curved glass panel, 2 curved encapsulation backplane, 3 colored light film layer, 31 light-transmitting base film layer, 311 nanometer imprinted grating, 32 colored coating layer, 4 curved cell layer, 41 crystalline silicon cell string layer, 411 half cell, 412 solder ribbon, 5 first encapsulant layer, 6 second encapsulant layer, 7 third encapsulant layer. Detailed Implementation

[0037] To better understand the above-mentioned objectives, features, and advantages of this application, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0038] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below.

[0039] The following reference Figures 1 to 5 This application describes a color photovoltaic module for automobiles and its preparation method according to some embodiments.

[0040] like Figure 1 As shown, an embodiment of this application provides a color photovoltaic module 100 for automobiles, including: a curved glass panel 1; a curved encapsulation backplate 2, disposed opposite to the curved glass panel 1; a color light film layer 3, disposed between the curved glass panel 1 and the curved encapsulation backplate 2, the color light film layer 3 including a light-transmitting base film layer 31 and a color coating layer 32 disposed on the light-transmitting base film layer 31, the color coating layer 32 being composed of at least two layers of inorganic materials with different refractive indices stacked together, and the refractive indices of adjacent inorganic materials being different, the color coating layer 32 selectively reflects incident light through optical interference between each inorganic material layer to present structural color; a curved battery layer 4, disposed between the color light film layer 3 and the curved encapsulation backplate 2; wherein, the curved glass panel 1, the color light film layer 3, the curved battery layer 4 and the curved encapsulation backplate 2 are stacked sequentially, and the curved shape of the laminated color light film layer 3, the curved battery layer 4 and the curved encapsulation backplate 2 matches the shape of the curved glass panel 1.

[0041] The automotive-grade colored photovoltaic module 100 provided in this application includes a curved glass panel 1, a curved encapsulation backplate 2, a colored light film layer 3, and a curved cell layer 4. The curved glass panel 1 serves as the outermost layer of the module, transmitting incident light and providing mechanical support and physical protection. The curved encapsulation backplate 2 is disposed opposite to the curved glass panel 1, sealing the back of the module to prevent moisture and impurities from entering. The colored light film layer 3 is disposed between the curved glass panel 1 and the curved encapsulation backplate 2. The colored light film layer 3 includes a light-transmitting base film layer 31 and a colored coating layer 32 disposed on the light-transmitting base film layer 31. The light-transmitting base film layer 31 is a polymer film, used to support the colored coating layer 32 and allow light to pass through. The colored coating layer 32 is composed of at least two layers of inorganic materials with different refractive indices, with adjacent inorganic material layers having different refractive indices. The colored coating layer 32 selectively reflects incident light using optical interference between the inorganic material layers, thereby exhibiting structural color. Structural color refers to the color produced by the interference, diffraction, or scattering of incident light by the microstructure of an object's surface, distinct from chemical color, which is produced by chemical dyes or pigments absorbing specific wavelengths. A curved battery layer 4 is disposed between the colored light film layer 3 and the curved encapsulation backplate 2, used to convert a portion of the incident light transmitted through the colored light film layer 3 into electrical energy. The curved glass panel 1, colored light film layer 3, curved battery layer 4, and curved encapsulation backplate 2 are sequentially stacked. After lamination, the curved shapes of the colored light film layer 3, curved battery layer 4, and curved encapsulation backplate 2 match the shape of the curved glass panel 1.

[0042] When the automotive colored photovoltaic module 100 is working, sunlight first passes through the curved glass panel 1 and reaches the colored light film layer 3. The colored coating layer 32 reflects specific wavelengths of colored light through optical interference, while the remaining wavelengths of light that are not reflected continue to pass through the light-transmitting base film layer 31 and enter the curved battery layer 4. The curved battery layer 4 absorbs this light energy and generates a photocurrent. The curved structure design of the automotive colored photovoltaic module 100 allows the entire module to be integrated into curved body parts such as the roof and hood without compromising the aesthetics of the vehicle's overall design. The colored light film layer 3 uses optical interference of inorganic material layers to generate structural colors, avoiding fading and aging of organic pigments or dyes under long-term sunlight exposure, resulting in high color stability. The light reflected by the structural colors does not participate in power generation, but the reflected wavelength can be precisely designed, minimizing its impact on the remaining transmitted light, thus maintaining a high photoelectric conversion efficiency for the curved battery layer 4.

[0043] Optionally, the automotive-grade colored photovoltaic module 100 further includes: a first encapsulating film layer 5, connecting the curved glass panel 1 and the colored light film layer 3; a second encapsulating film layer 6, connecting the colored light film layer 3 and the curved cell layer 4; and a third encapsulating film layer 7, connecting the curved cell layer 4 and the curved encapsulation backplate 2. That is, the first encapsulating film layer 5 connects the curved glass panel 1 and the colored light film layer 3, the second encapsulating film layer 6 connects the colored light film layer 3 and the curved cell layer 4, and the third encapsulating film layer 7 connects the curved cell layer 4 and the curved encapsulation backplate 2. During the lamination process, the multiple encapsulating film layers fill the curved gaps between the layers, ensuring the bonding strength and optical transparency between the layers, ultimately resulting in an automotive-grade colored photovoltaic module 100 with good weather resistance, long-lasting color, and excellent power generation performance.

[0044] Alternatively, in some embodiments, such as Figure 1 and Figure 2 As shown, the surface of the light-transmitting base film layer 31 is provided with a nano-imprinted grating 311. The light-transmitting base film layer 31 is a polyethylene terephthalate film or a polyamide film with a thickness greater than or equal to 15 μm and less than or equal to 25 μm. The total number of layers in the color coating layer 32 is an odd number. The thickness of each layer in the color coating layer 32 is different and they are distributed in a non-arithmetic or non-geometric sequence.

[0045] In this embodiment, a nanoimprint grating 311 is provided on the surface of the light-transmitting base film layer 31. The nanoimprint grating 311 is a periodic micro-nano structure formed on the surface of the light-transmitting base film layer 31 by a nanoimprinting process. It is used to diffract or scatter incident light to assist or modulate the structural color presented by the color coating layer 32. The light-transmitting base film layer 31 is made of polyethylene terephthalate film or polyamide film, and the thickness of the light-transmitting base film layer 31 is greater than or equal to 15 μm and less than or equal to 25 μm. This thickness range can ensure the mechanical strength and dimensional stability of the light-transmitting base film layer 31, and can also adapt to changes in curved shape during the lamination process without cracking or wrinkling. The color coating layer 32 is composed of at least two layers of inorganic materials with different refractive indices stacked together, and the total number of layers of the color coating layer 32 is an odd number. The odd-numbered layer structure makes the outermost and innermost layers of the color coating layer 32 have the same or similar optical boundary conditions, which is beneficial to improve the contrast of optical interference and make the reflected color more saturated and pure. Meanwhile, the thicknesses of the inorganic material layers in the colored coating layer 32 are different, and the thicknesses of each layer are distributed in a non-arithmetic or non-geometric order. This non-arithmetic or non-geometric thickness distribution avoids periodic thickness variations, thereby broadening the reflection spectrum or forming a specific color response curve, suppressing secondary interference peaks caused by regular thickness variations, and resulting in higher color purity and angular stability of the final structural color. In other words, the nanoimprinted grating 311 on the surface of the transparent base film layer 31 produces a weak diffraction effect on the incident light, dispersing some of the light to different angles. Combined with the multi-beam interference effect of the colored coating layer 32, this ensures that the color of the reflected light maintains minimal change or exhibits the expected gradient effect at different viewing angles. Therefore, the synergistic effect of the nanoimprint grating 311 and the color coating layer 32 can expand the color gamut of the structural color and improve the color shift problem at large angles, so that the color photovoltaic module 100 of the vehicle can have a consistent color performance in different parts of the curved surface of the vehicle body. Furthermore, the color photovoltaic module 100 of the vehicle can present a stable, rich and weather-resistant color appearance while maintaining high photoelectric conversion efficiency, thus meeting the requirements of automobile manufacturing for color quality and reliability.

[0046] Alternatively, in some embodiments, such as Figure 1 and Figure 2 As shown, the inorganic material includes at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. The total number of layers in the color coating layer 32 is greater than or equal to 3, and the thickness of each layer of the color coating layer 32 is greater than or equal to 50 nm and less than or equal to 210 nm.

[0047] In this embodiment, the colored coating layer 32 is composed of at least two inorganic materials stacked together. These inorganic materials include at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. Silicon dioxide has a low refractive index, titanium dioxide has a high refractive index, aluminum-doped zinc oxide combines conductivity with a moderate refractive index, and silicon nitride has a high refractive index and good density. The inorganic materials selected in this application all possess high hardness, high weather resistance, and low light absorption, ensuring that the colored coating layer 32 does not fade or decompose under long-term ultraviolet irradiation and temperature cycling, and that a strong multi-beam interference effect is generated at the interfaces between layers. A total of three or more layers enhances the contrast of the interference effect, producing purer colors compared to a two-layer structure. The thickness of each layer is controlled between 50 nm and 210 nm, avoiding discontinuities or pinhole defects caused by excessive thinness, and avoiding unnecessary film stress or color shift caused by excessive thickness. Meanwhile, the thickness range of each layer is compatible with the curved lamination process, maintaining the stability of the film structure under the lamination temperature and pressure of the curved glass panel 1 and the curved encapsulation backplate 2, thereby providing a durable, uniform and designable color appearance for the automotive colored photovoltaic module 100.

[0048] Optionally, in some embodiments, the total number of layers of the color coating layer 32 is 7, the thickness of each layer of the color coating layer 32 is greater than or equal to 50 nm and less than or equal to 200 nm, and the total thickness is greater than or equal to 400 nm and less than or equal to 1300 nm.

[0049] In this embodiment, the total number of color coating layers 32 is 7, ensuring that the outermost and innermost layers of the color coating layers 32 have the same optical boundary conditions, which is beneficial for forming a high-contrast interference spectrum. Simultaneously, the total number of 7 layers ensures a sufficient number of interference optical paths, resulting in a high peak reflectivity of the reflection spectrum. The thickness of each layer of the color coating layers 32 is independently selected within the range of 50nm to 200nm, and the total thickness is controlled between 400nm and 1300nm, allowing the center wavelength of the reflection peak to be precisely located in the blue, green, red, or intermediate color regions of the visible spectrum. Unreflected light of other wavelengths passes through the color coating layer 3 and enters the curved battery layer 4, where the curved battery layer 4 converts the transmitted light into electrical energy. Therefore, the automotive color photovoltaic module 100 of this application provides precisely controllable structural color while maintaining high incident light utilization.

[0050] By adjusting the type and thickness of the inorganic materials in each layer of the colored light film layer 32, various structural colors, such as red, green, blue, and yellow, can be modulated. Different structural colors correspond to different transmittance and photoelectric conversion efficiency. Some colors can achieve higher transmittance while maintaining high color saturation, thereby allowing more incident light to pass through the colored light film layer 3 to reach the curved battery layer 4, thus improving the overall photoelectric conversion efficiency.

[0051] Optionally, the colored coating layer adopts a 7-layer deposition structure, with the materials sequentially selected as aluminum-doped zinc oxide, silicon dioxide, and titanium dioxide, and each layer having a different thickness to form a non-periodic interference optical film. Specifically, starting from the side closest to the transparent base film layer, the first layer is titanium dioxide with a thickness of 68 nm; the second layer is silicon dioxide with a thickness of 112 nm; the third layer is aluminum-doped zinc oxide with a thickness of 55 nm; the fourth layer is silicon dioxide with a thickness of 135 nm; the fifth layer is titanium dioxide with a thickness of 72 nm; the sixth layer is silicon dioxide with a thickness of 98 nm; and the seventh layer is aluminum-doped zinc oxide with a thickness of 60 nm. This application uses magnetron sputtering to sequentially deposit multiple layers of colored coating 32 onto the transparent base film layer 31, which can achieve high reflectivity saturation and high transmittance for grass green or other target colors, taking into account both the colored appearance of curved roofs and power generation performance.

[0052] Alternatively, in some embodiments, such as Figure 1 and Figure 2 As shown, the thickness of the curved glass panel 1 is greater than or equal to 2 mm and less than or equal to 3.5 mm, the radius of curvature is greater than or equal to 2.5 m and less than or equal to 3.5 m, and the vertical distance from the edge of the curved glass panel 1 to the highest point is greater than or equal to 0.2 m and less than or equal to 0.3 m.

[0053] In this embodiment, the thickness of the curved glass panel 1 is greater than or equal to 2 mm and less than or equal to 3.5 mm. This thickness range provides the curved glass panel 1 with sufficient impact resistance while maintaining appropriate light transmittance to allow sunlight to enter the interior of the automotive colored photovoltaic module 100. The radius of curvature of the curved glass panel 1 is greater than or equal to 2.5 m and less than or equal to 3.5 m. Figure 1 As shown, the vertical distance from the edge of the curved glass panel 1 to its highest point is h, where h is greater than or equal to 0.2m and less than or equal to 0.3m. The curved surface parameters match the shape of the car roof or hood, allowing the automotive color photovoltaic module 100 to be installed on the vehicle body surface and form a continuous appearance contour with the surrounding sheet metal parts. Therefore, the thickness of the curved glass panel 1 is between 2mm and 3.5mm, balancing lightweight and structural strength. The limitations on the radius of curvature and arch height result in a high yield rate for hot bending of the glass and compatibility with existing automotive glass shapes. The matching curved surface shape reduces the negative impact of the automotive color photovoltaic module 100 on the vehicle's aerodynamic characteristics and also facilitates the sliding off of rainwater and dirt. The automotive color photovoltaic module 100 can be reliably installed on the curved surface of the vehicle body, providing long-lasting color power generation without compromising the overall aesthetic design of the vehicle.

[0054] Optionally, in some embodiments, the curved encapsulation backplate 2 is made of a light-transmitting polymer material, including any one of transparent CPC, transparent PET, transparent PC or transparent PMMA; the thickness of the curved encapsulation backplate 2 is greater than or equal to 0.3 mm and less than or equal to 0.4 mm.

[0055] In this embodiment, the curved encapsulation backplate 2 is made of a light-transmitting polymer material, including any one of transparent CPC, transparent PET, transparent PC, or transparent PMMA. The thickness of the curved encapsulation backplate 2 is greater than or equal to 0.3 mm and less than or equal to 0.4 mm. This thickness range allows the curved encapsulation backplate 2 to maintain sufficient moisture barrier and electrical insulation performance while possessing sufficient flexibility to adapt to the curved lamination process. The curved encapsulation backplate 2 is positioned opposite to the curved glass panel 1 and is used to seal the back of the automotive color photovoltaic module 100, preventing moisture, oxygen, and dust from penetrating the curved battery layer 4 from the back. Therefore, the curved encapsulation backplate 2, made of transparent CPC, transparent PET, transparent PC, or transparent PMMA, with a thickness controlled between 0.3 mm and 0.4 mm, reduces the overall weight of the automotive color photovoltaic module 100 while ensuring sufficient mechanical support and insulation protection. The light-transmitting characteristics allow the automotive color photovoltaic module 100 to be made in a semi-transparent or bi-sided power generation form, suitable for installation in areas requiring light transmission, such as car sunroofs or rear windows. Meanwhile, the polymer material at the aforementioned thickness has good thermoforming ability and can maintain the same curvature as the curved glass panel 1, avoiding springback or delamination after lamination, thereby ensuring the reliability and appearance consistency of the automotive color photovoltaic module 100 in long-term vehicle vibration and temperature change environments.

[0056] Alternatively, in some embodiments, such as Figure 1 , Figure 2 and Figure 3 As shown, the curved battery layer 4 includes a crystalline silicon battery string layer 41, which includes at least one of a full back contact battery, a tunnel oxide passivated contact battery, or a heterojunction battery.

[0057] In this embodiment, the curved battery layer 4 includes a crystalline silicon battery string layer 41. The crystalline silicon battery string layer 41 is composed of multiple crystalline silicon cells connected in series or parallel via conductive connectors, used to convert light energy into electrical energy. The crystalline silicon battery string layer 41 includes at least one of a full-back contact battery, a tunneling oxide passivated contact battery, or a heterojunction battery. Using a full-back contact battery avoids the front grid lines blocking light, allowing more light to enter the effective area of ​​the battery, thereby improving the conversion efficiency of the automotive color photovoltaic module 100. Using a tunneling oxide passivated contact battery reduces the back recombination rate, making it suitable for environments with double-sided light exposure or low light conditions. Using a heterojunction battery maintains high power output at high temperatures, making it suitable for installation on locations such as the roof where temperatures rise rapidly under sunlight. The curved adaptability of the crystalline silicon battery string layer 41 in the curved battery layer 4 allows the automotive color photovoltaic module 100 to closely conform to the vehicle body contours while maintaining high photoelectric conversion performance.

[0058] Alternatively, in some embodiments, such as Figure 1 , Figure 2 and Figure 3 As shown, the crystalline silicon cell string layer 41 includes multiple half-cells 411, which are arranged sequentially along the direction perpendicular to the thickness, and adjacent half-cells 411 are connected in series by solder strips 412 to form the crystalline silicon cell string layer 41.

[0059] In this embodiment, the crystalline silicon cell string layer 41 includes multiple half-cells 411. A half-cell 411 is a cell unit formed by cutting a standard-sized crystalline silicon cell in half along its length. The area of ​​each half-cell 411 is approximately half that of the original cell, resulting in a correspondingly lower operating current. Multiple half-cells 411 are arranged sequentially along a direction perpendicular to the thickness of the curved cell layer 4, i.e., multiple half-cells 411 are arranged sequentially in the planar direction of the curved cell layer 4. Adjacent half-cells 411 are connected in series by solder ribbons 412 to form a cell string. The solder ribbons 412 are copper strips coated with low-melting-point solder. During soldering, the solder melts and connects the front electrode of one half-cell 411 to the back electrode of the adjacent half-cell 411, achieving electrical series connection. After multiple half-cells 411 are connected in series, positive and negative electrodes are led out from both ends of the cell string for current collection. Therefore, this application uses half-cell batteries 411 instead of full-cell batteries, reducing the operating current of each battery cell, thereby reducing heat loss due to resistance on the solder ribbon 412 and electrodes, and improving the output power of the automotive color photovoltaic module 100. Multiple half-cell batteries 411 are arranged sequentially along the curved surface and connected in series via solder ribbon 412, giving the curved battery layer 4 excellent flexibility and adaptability, allowing it to fit tightly against the curved surface of the glass panel 1 without cell breakage. The welding connection method ensures the electrical reliability of the crystalline silicon battery string layer 41; even in a vehicle vibration environment, the solder joints will not loosen, improving the long-term stability of the automotive color photovoltaic module 100.

[0060] Optionally, the first adhesive layer 5 includes one of POE film, EVA film or EPE film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm; and / or the second adhesive layer 6 includes one of POE film, EVA film or EPE film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm; and / or the third adhesive layer 7 includes one of POE film, EVA film or EPE film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm.

[0061] In this embodiment, the first adhesive film layer 5 connects the curved glass panel 1 and the colored light film layer 3. The first adhesive film layer 5 includes one of POE film, EVA film, or EPE film, with a thickness greater than or equal to 0.5 mm and less than or equal to 0.7 mm. POE film is a polyolefin elastomer film with low water vapor transmission rate and high volume resistivity. EVA film is an ethylene-vinyl acetate copolymer film with good flowability and adhesion. EPE film is a co-extruded composite film of EVA and POE, combining some of the advantages of both. The first adhesive film layer 5, the second adhesive film layer 6, and the third adhesive film layer 7 can be made of the same material to simplify the process, or different materials can be selected according to their respective positions to optimize performance. For example, the first adhesive film layer 5 can be made of high light transmittance EVA, the second adhesive film layer 6 can be made of anti-aging POE, and the third adhesive film layer 7 can be made of EPE, which has both adhesion and water-blocking properties. During the curved lamination process, the three layers of adhesive film melt and solidify simultaneously, pressing the curved glass panel 1, the colored light film layer 3, the curved battery layer 4, and the curved encapsulation backplate 2 into a whole, and making the curved shapes of each layer match each other, while ensuring the reliability of interlayer bonding and long-term weather resistance of the automotive colored photovoltaic module 100 in the curved shape.

[0062] Optionally, the thickness of the first adhesive layer 5 is greater than or equal to 0.55 mm and less than or equal to 0.7 mm, the thickness of the second adhesive layer 6 is greater than or equal to 0.55 mm and less than or equal to 0.7 mm, and the thickness of the third adhesive layer 7 is greater than or equal to 0.55 mm and less than or equal to 0.7 mm.

[0063] Based on the same technical concept, the second aspect of this application proposes a method for preparing a color photovoltaic module for automobiles, used to prepare the color photovoltaic module for automobiles as proposed in the first aspect, such as... Figure 5 As shown, the method for manufacturing automotive color photovoltaic modules includes:

[0064] S101: An inorganic material layer is deposited on a transparent base film layer by magnetron sputtering;

[0065] S103: Another inorganic material layer is deposited on the previously deposited inorganic material layer using magnetron sputtering, and the refractive indices of the two adjacent inorganic material layers are different;

[0066] S105: Continue to deposit new inorganic material layers using magnetron sputtering until a colored coating layer that meets the preset requirements is formed. The transparent base film layer and the colored coating layer together form a colored light film layer.

[0067] S107: The curved glass panel, the first adhesive film layer, the colored light film layer, the second adhesive film layer, the curved battery layer, the third adhesive film layer and the curved encapsulation backplate are stacked sequentially to form a stacked structure;

[0068] S109: Place the laminated structure on a mold that matches the shape of the curved glass panel;

[0069] S111: Place the mold with the stacked structure into a vacuum bag and vacuum the vacuum bag.

[0070] S113: Lamination is performed under vacuum to bond and cure the materials of each layer, resulting in automotive colored photovoltaic modules.

[0071] According to the fabrication method of the automotive color photovoltaic module provided in this application, firstly, an inorganic material layer is deposited on a transparent substrate layer using magnetron sputtering. Then, another inorganic material layer is deposited on top of the previously deposited inorganic material layer using magnetron sputtering, with adjacent inorganic material layers having different refractive indices. The power density of the magnetron sputtering is greater than or equal to 3 W / cm². 2 And less than or equal to 10W / cm 2 This method ensures effective sputtering of target atoms while avoiding excessive power that could lead to a porous film structure or overheating and deformation of the substrate. The target evaporation rate is greater than or equal to 50 nm / h and less than or equal to 100 nm / h, resulting in a dense and uniform film and reducing pinholes and stress defects. The deposition process is repeated, depositing layers sequentially according to a predetermined number of layers until a colored coating layer meeting the preset requirements is formed. The colored coating layer consists of at least two layers of inorganic materials with different refractive indices stacked together. The incident light is selectively reflected through optical interference between the inorganic material layers to reveal the structural color.

[0072] After the colored light film layer is prepared, the curved glass panel, the first encapsulating film layer, the colored light film layer, the second encapsulating film layer, the curved battery layer, the third encapsulating film layer, and the curved encapsulation backplate are sequentially stacked to form a laminated structure. The laminated structure is then placed on a mold that matches the shape of the curved glass panel. The curved shape of the mold matches the curved shape of the glass panel, serving to support and maintain the curved shape of the laminated structure in subsequent processes. The mold containing the laminated structure is placed in a vacuum bag, and the vacuum bag is then evacuated. The vacuum level is controlled between -25 kPa and -10 kPa to effectively remove air bubbles from the laminated structure without causing excessive pressure that could crush the curved glass panel or cause microcracks in the battery cells. Lamination is then performed under vacuum conditions at a temperature greater than or equal to 140°C and less than or equal to 150°C for a lamination time greater than or equal to 35 minutes and less than or equal to 50 minutes. During this process, the first, second, and third adhesive film layers melt under heat and flow under vacuum pressure, filling the curved gaps between the layers. Simultaneously, this presses together the curved glass panel, the colored light film layer, the curved battery layer, and the curved encapsulation backplate. After lamination, the adhesive film layers cool and solidify, bonding each layer into a single unit, resulting in a color photovoltaic module for automobiles. The entire manufacturing method is adapted to the specific radius of curvature and arch height of the curved glass panel. The mold and vacuum bag ensure that the curved shapes of the colored light film layer, the curved battery layer, and the curved encapsulation backplate match the shape of the curved glass panel after lamination, thus enabling mass production of color photovoltaic modules for automobiles with stable color, reliable interlayer bonding, and adaptability to the curved surfaces of the vehicle body.

[0073] Optionally, in some embodiments, the inorganic material includes at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. The preset requirements include that the total number of layers of the color coating is an odd number and greater than or equal to 3 layers, and that the thickness of each layer of the color coating is greater than or equal to 50 nm and less than or equal to 210 nm.

[0074] In this embodiment, the inorganic material deposited by magnetron sputtering includes at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. Prerequisites include an odd number of layers and at least three layers in the total number of colored coating layers, and each layer's thickness being at least 50 nm and less than or equal to 210 nm. Alternating deposition of at least two inorganic materials with significantly different refractive indices creates a strong multi-beam interference effect, resulting in highly saturated and bright structural colors. Using an odd number of layers and at least three layers ensures that the outermost and innermost layers of the colored coating are under similar optical boundary conditions, effectively improving the contrast of the interference spectrum and preventing the reflected colors from becoming dark or whitish. Simultaneously, the color of the automotive colored photovoltaic module will not fade under long-term outdoor sunlight and temperature changes, while maintaining high light transmittance and avoiding significant loss of power generation efficiency in the curved battery layer.

[0075] In one specific application, this application provides a curved colored car roof photovoltaic module and its manufacturing process. For example... Figures 1 to 4 As shown, in the encapsulation structure of the curved colored roof photovoltaic module, the front panel glass is preferably fully tempered curved glass with a radius of curvature greater than or equal to 2.5m and less than or equal to 3.5m, an arch height greater than or equal to 0.2m and less than or equal to 0.3m, a thickness greater than or equal to 2.0mm and less than or equal to 3.2mm, and a light transmittance greater than 91%. The first encapsulation layer is preferably a high-cutoff POE encapsulation film, where high cutoff refers to the POE encapsulation film having a high ultraviolet cutoff capability. EVA or EPE encapsulation films are the next most preferred, with a thickness greater than or equal to 0.55mm and less than or equal to 0.7mm. The colored coating layer is deposited on a transparent polymer film using a roll-to-roll process via magnetron sputtering. The second encapsulation layer is preferably a high-transparency encapsulation EVA encapsulation film, and POE or EPE encapsulation films are the next most preferred, with a thickness greater than or equal to 0.55mm and less than or equal to 0.7mm. The preferred crystalline silicon solar cell string is an XBC (Cross-Back Contact Cell), followed by a TOPCon (Tunnel Oxide Passivated Contact Cell) or HJT (Heterojunction Solar Cell), constructed by stringing together half-cells. The light-receiving side of the cell string is protected by a transparent front panel, and the back-lighting side is protected by a backplate. A first and second encapsulating film layer bonds the front panel, the cell string, and the backplate. The encapsulation backplate is preferably transparent CPC, followed by transparent PET, transparent PC, or transparent PMMA, with a thickness greater than or equal to 0.3 mm and less than or equal to 0.4 mm.

[0076] The encapsulation process for curved colored roof photovoltaic modules is as follows: Each layer of material is laid out sequentially and fixed in place to ensure no relative displacement between layers. Then, the entire laminated structure is placed on an aluminum module with a shape consistent with the curved glass, the aluminum module being larger than the curved glass. The aluminum module with the laminated structure is placed in a vacuum bag. After the equipment is shut down, the vacuum bag is evacuated, with the vacuum level controlled between -25 kPa and -10 kPa. The lamination temperature is controlled between 140°C and 150°C, and the entire lamination process takes between 35 and 50 minutes.

[0077] In the colored transparent film layer, the transparent polymer film is preferably a transparent polyethylene terephthalate film, and secondarily a transparent polyamide film. The thickness of the polymer film is greater than or equal to 15 μm and less than or equal to 25 μm. A nanoimprint grating made of transparent UV-curable epoxy resin is imprinted on the polymer film. On the polymer film with the nanoimprint grating, two or three combinations of materials selected from silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride are deposited using a roll-to-roll process via magnetron sputtering. The thickness of the colored film layer is controlled by adjusting the sputtering power density and the target evaporation rate. The magnetron sputtering power density is controlled to be greater than or equal to 3 W / cm². 2 And less than or equal to 10W / cm 2 The target evaporation rate was controlled to be greater than or equal to 50 nm / h and less than or equal to 100 nm / h. Magnetron sputtering deposition was performed using grass green as the target color, with an alternating structure of silicon nitride, silicon dioxide, and titanium dioxide. The number of deposition layers was an odd number, specifically 3, 5, 7, 9, or 11 layers. The deposition structure and deposition effect are shown in Table 1.

[0078] Table 1

[0079]

[0080] In preparing the colored coating layer, three inorganic materials—aluminum-doped zinc oxide, silicon dioxide, and titanium dioxide—were selected sequentially. The target material for the aluminum-doped zinc oxide contained 2 wt% aluminum and 98 wt% zinc oxide. The preferred colored coating layer structure was a 7-layer deposition structure, with layers of varying thickness deposited sequentially using magnetron sputtering. Each layer had a different thickness and an aperiodic distribution. By designing an aperiodic interference optical film, the control of different colored transparent films was achieved, allowing the colored coating layer to exhibit the desired structural color. Compared to traditional colored glass and enamel-coated glass, this application can adapt to different sizes and geometries, offering operational flexibility and saving processing time. The results are shown in Table 2.

[0081] Table 2

[0082]

[0083] The curved colored roof photovoltaic module laminated with the above-mentioned encapsulation structure was subjected to power testing using an IV tester. The test results are shown in Table 3.

[0084] Table 3

[0085]

[0086] In this application, the term "multiple" refers to two or more unless otherwise expressly defined. The terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0087] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0088] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A colored photovoltaic module for automotive applications, characterized in that, include: Curved glass panel; A curved encapsulation backplate is disposed opposite to the curved glass panel; A colored light film layer is disposed between the curved glass panel and the curved encapsulation backplate. The colored light film layer includes a light-transmitting base film layer and a colored coating layer disposed on the light-transmitting base film layer. The colored coating layer is composed of at least two layers of inorganic materials with different refractive indices, and the refractive indices of adjacent inorganic material layers are different. The colored coating layer selectively reflects incident light through optical interference between the inorganic material layers to present structural colors. A curved battery layer is disposed between the colored light film layer and the curved encapsulation backplate; The curved glass panel, the colored light film layer, the curved battery layer, and the curved encapsulation backplate are stacked sequentially, and the curved shapes of the laminated colored light film layer, curved battery layer, and curved encapsulation backplate match the shape of the curved glass panel.

2. The automotive color photovoltaic module according to claim 1, characterized in that, The surface of the light-transmitting base film layer is provided with a nano-imprinted grating. The light-transmitting base film layer is a polyethylene terephthalate film or a polyamide film with a thickness greater than or equal to 15 μm and less than or equal to 25 μm. The total number of colored coating layers is an odd number, and the thickness of each layer in the colored coating layer is different and they are distributed in a non-arithmetic or non-geometric sequence.

3. The automotive color photovoltaic module according to claim 2, characterized in that, The inorganic material includes at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. The total number of layers in the colored coating layer is greater than or equal to three, and the thickness of each layer in the colored coating layer is greater than or equal to 50 nm and less than or equal to 210 nm.

4. The automotive color photovoltaic module according to claim 3, characterized in that, The total number of layers in the color coating layer is 7. The thickness of each layer is greater than or equal to 50 nm and less than or equal to 200 nm, and the total thickness is greater than or equal to 400 nm and less than or equal to 1300 nm.

5. The automotive color photovoltaic module according to claim 1, characterized in that, The thickness of the curved glass panel is greater than or equal to 2 mm and less than or equal to 3.5 mm, the radius of curvature is greater than or equal to 2.5 m and less than or equal to 3.5 m, and the vertical distance from the edge of the curved glass panel to the highest point is greater than or equal to 0.2 m and less than or equal to 0.3 m.

6. The automotive color photovoltaic module according to claim 1, characterized in that, The curved encapsulation backplate is made of a light-transmitting polymer material, which includes any one of transparent CPC, transparent PET, transparent PC or transparent PMMA. The thickness of the curved encapsulation backplate is greater than or equal to 0.3 mm and less than or equal to 0.4 mm.

7. The automotive color photovoltaic module according to claim 1, characterized in that, The curved battery layer includes a crystalline silicon battery string layer, which includes at least one of a full back contact battery, a tunnel oxide passivated contact battery, or a heterojunction battery.

8. The automotive color photovoltaic module according to claim 7, characterized in that, The crystalline silicon cell string layer includes multiple half-cells, which are arranged sequentially along a direction perpendicular to the thickness, and adjacent half-cells are connected in series by solder strips to form the crystalline silicon cell string layer.

9. A method for preparing a colored photovoltaic module for automobiles, characterized in that, A method for preparing a color photovoltaic module for automobiles as described in any one of claims 1 to 8, the method comprising: An inorganic material layer was deposited on a transparent substrate layer using magnetron sputtering. The magnetron sputtering method is used to deposit another inorganic material layer on the already deposited inorganic material layer, and the refractive indices of the two adjacent inorganic material layers are different; The magnetron sputtering method is used to continue depositing new inorganic material layers until a colored coating layer that meets the preset requirements is formed. The light-transmitting base film layer and the colored coating layer together form a colored light film layer. The curved glass panel, the colored light film layer, the curved battery layer, and the curved encapsulation backplate are stacked sequentially to form a layered structure. The laminated structure is placed on a mold that matches the shape of the curved glass panel; The mold containing the stacked structure is placed into a vacuum bag, and the vacuum bag is then vacuumed. The lamination process is carried out under vacuum to bond and cure the materials of each layer, thus obtaining the automotive color photovoltaic module. The parameters of the magnetron sputtering method include a power density of 3 W / cm². 2 And less than or equal to 10W / cm 2 The target evaporation rate is greater than or equal to 50 nm / h and less than or equal to 100 nm / h, the vacuum degree of the vacuuming process is controlled between -25 kPa and -10 kPa, the lamination temperature is greater than or equal to 140°C and less than or equal to 150°C, and the lamination time is greater than or equal to 35 min and less than or equal to 50 min.

10. The method for preparing a color photovoltaic module for automobiles according to claim 9, characterized in that, The inorganic material includes at least two of silicon dioxide, titanium dioxide, aluminum-doped zinc oxide, and silicon nitride. The preset requirements include that the total number of layers of the colored coating layer is an odd number and greater than or equal to 3 layers, and that the thickness of each layer of the colored coating layer is greater than or equal to 50 nm and less than or equal to 210 nm.

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