A rollable solar cell module and a method of manufacturing the same

Abstract

The application provides a rollable solar cell module and a preparation method thereof, and relates to the technical field of solar cells. The rollable solar cell module comprises a hollow flexible support layer, a first adhesive layer located on one side of the hollow flexible support layer, and an ultrathin crystalline silicon power generation layer located on the side of the adhesive layer away from the hollow flexible support layer, and the thickness of the ultrathin crystalline silicon power generation layer is below 100 micrometers. The hollow area of the hollow flexible support layer accounts for 35% to 45%, and the hollow flexible support layer, the first adhesive layer and the ultrathin crystalline silicon power generation layer are integrally formed by using a laminating process. The preparation method of the rollable solar cell module is used for preparing the rollable solar cell module. The rollable solar cell module provided by the application realizes flexible rolling of the overall structure, is convenient for transportation, and can be adapted to a curved surface installation scene.

Description

Technical Field

[0001] This invention relates to the field of solar cell technology, and more specifically, to a rollable solar cell module and its preparation method. Background Technology

[0002] Traditional crystalline silicon photovoltaic modules are encapsulated using rigid materials such as tempered glass and polymer films, which have drawbacks such as heavy weight, inflexibility, inconvenient transportation and installation, and inability to adapt to curved surfaces, thus limiting their application scenarios. Furthermore, when the thickness of crystalline silicon solar cells is reduced to the ultra-thin range of less than 100 μm, their structural strength is extremely low and their brittleness is significant, making them prone to breakage, microcracks, or warping deformation during transportation and use, which restricts the convenience of transportation and use.

[0003] In view of this, designing and manufacturing a rollable solar cell module for ultrathin crystalline silicon cells is of particular importance in the field of solar cell technology. Summary of the Invention

[0004] The purpose of this invention is to provide a rollable solar cell module that integrates an ultra-thin crystalline silicon power generation layer onto a hollow flexible support layer, enabling the overall structure to be flexibly rolled up, facilitating transportation, and adapting to curved surface installation scenarios.

[0005] Another objective of this invention is to provide a method for preparing a rollable solar cell module. The prepared rollable solar cell module can be flexibly rolled up, which facilitates transportation and can be adapted to curved surface installation scenarios.

[0006] The present invention is achieved by the following technical solution.

[0007] In a first aspect, the present invention provides a rollable solar cell module, including a hollow flexible support layer, a first adhesive layer located on one side of the hollow flexible support layer, and an ultra-thin crystalline silicon power generation layer located on the side of the first adhesive layer away from the hollow flexible support layer, wherein the thickness of the ultra-thin crystalline silicon power generation layer is less than 100 μm. The hollow area of ​​the hollow flexible support layer accounts for 35% to 45%, and the hollow flexible support layer, the first adhesive layer and the ultra-thin crystalline silicon power generation layer are integrally cured and formed by lamination process.

[0008] Optionally, the thickness of the perforated flexible support layer is in the range of 0.1 mm to 0.5 mm.

[0009] Optionally, the thickness of the ultrathin crystalline silicon power generation layer is in the range of 40 μm to 90 μm.

[0010] Optionally, the rollable solar cell module further includes a first encapsulation layer, a second encapsulation layer, a second adhesive layer and a third adhesive layer, wherein the first encapsulation layer is located on the side of the crystalline silicon power generation layer away from the hollow flexible support layer, and the second encapsulation layer is located on the side of the hollow flexible support layer away from the ultrathin crystalline silicon power generation layer. The second adhesive layer is located between the hollow flexible support layer and the second encapsulation layer, and the third adhesive layer is located between the crystalline silicon power generation layer and the first encapsulation layer.

[0011] Optionally, the first adhesive layer, the second adhesive layer, and the third adhesive layer are all selected from silicone, epoxy, acrylic, EVA film, and POE film.

[0012] Optionally, the crystalline silicon power generation layer includes an N-type ultrathin crystalline silicon cell or a P-type ultrathin crystalline silicon cell.

[0013] Optionally, the material of the hollow flexible support layer is selected from one of the following: composite material reinforcing fiber, flexible polymer film, metal alloy or semiconductor material.

[0014] Optionally, the hollow flexible support layer is made of one of carbon fiber, basalt fiber, or alkali-free glass fiber.

[0015] Optionally, the hollow flexible support layer is made of one of PMMA, PET, or PI.

[0016] Optionally, the flexible support layer can be made flexible through laser perforation.

[0017] Secondly, the present invention provides a method for preparing a rollable solar cell module, used to prepare the aforementioned rollable solar cell module. The preparation method includes: S001, The substrate of the hollow flexible support layer is processed by laser hollowing process to form a hollow flexible support layer with a hollow area ratio of 35% to 45%. S002, A first adhesive layer is coated on the surface of the hollow flexible support layer, and an ultrathin crystalline silicon power generation layer is stacked on the side of the first adhesive layer away from the hollow flexible support layer, and the hollow flexible support layer, the first adhesive layer and the ultrathin crystalline silicon power generation layer form a pre-stacked structure. S003, The pre-stacked structure is placed in a vacuum laminator and laminated and cured at a temperature of 80-100℃ to form a single unit.

[0018] The beneficial effects of the rollable solar cell module provided by this invention include: The rollable solar cell module provided by this invention includes a perforated flexible support layer, a first adhesive layer located on one side of the perforated flexible support layer, and an ultrathin crystalline silicon power generation layer located on the side of the first adhesive layer away from the perforated flexible support layer. The thickness of the ultrathin crystalline silicon power generation layer is less than 100 μm. The perforated area of ​​the perforated flexible support layer accounts for 35% to 45%, and the perforated flexible support layer, the first adhesive layer, and the ultrathin crystalline silicon power generation layer are integrally cured and formed using a lamination process. Compared with the prior art, the rollable solar cell module provided by this invention integrates the ultrathin crystalline silicon power generation layer onto the perforated flexible support layer through the first adhesive layer, and controls the perforated area of ​​the perforated flexible support layer within the range of 35% to 45%. Therefore, the rollable solar cell module can maintain stable function after multiple bending and rolling, and can be adapted to curved surface installation scenarios.

[0019] The beneficial effects of the method for preparing a rollable solar cell module provided by this invention include: A laser-cutting process is used to process the substrate, forming a flexible support layer with a specific cutout area. An ultrathin crystalline silicon power generation layer is then integrated onto the flexible support layer via a first adhesive layer, forming a pre-stacked structure. This pre-stacked structure is integrally cured and formed at a temperature of 80℃~100℃ through a lamination process. The flexible support layer, the first adhesive layer, and the ultrathin crystalline silicon power generation layer are tightly bonded together without air bubbles, making them less prone to delamination during subsequent use. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the structure of the rollable solar cell module provided in this embodiment; Figure 2 A schematic diagram of the structure of a rollable solar cell module provided in another embodiment; Figure 3 This is a flowchart of a method for fabricating a rollable solar cell module.

[0022] Icons: 100 - Rollable solar cell module; 110 - Perforated flexible support layer; 120 - First adhesive layer; 130 - Ultra-thin crystalline silicon power generation layer; 140 - Second adhesive layer; 150 - Third adhesive layer; 160 - First encapsulation layer; 170 - Second encapsulation layer. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0024] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0025] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0026] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0027] Furthermore, the terms "first," "second," etc., are used only for distinguishing descriptions and should not be construed as indicating or implying relative importance. Also, in the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0028] It should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections, electrical connections, or connections that allow for communication; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0029] It should also be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.

[0030] As disclosed in the background section, existing technologies typically use rigid materials such as tempered glass and polymer films to support crystalline silicon solar cells, preventing them from cracking, developing microcracks, or warping during transportation and use, which could lead to malfunction of the solar cell module. However, the presence of rigid materials results in significant weight of the solar cell module during transportation, making transport and installation inconvenient. Furthermore, the lack of flexibility in practical applications prevents it from meeting the requirements for curved surface installations, severely limiting the performance of the solar cell module.

[0031] To address the aforementioned technical problems, this invention provides a rollable solar cell module and a method for preparing the rollable solar cell module. The method uses a hollow flexible support layer to modify the ultrathin crystalline silicon cell, enabling the solar cell module to be flexibly rolled up, facilitating transportation and adapting to curved surface installation scenarios.

[0032] Please refer to Figure 1 This application provides a rollable solar cell module 100, whose hollow flexible support layer 110 can effectively support the ultra-thin crystalline silicon power generation layer and can also achieve flexible roll-up together with it.

[0033] In a first aspect, this embodiment provides a rollable solar cell module 100, including a hollow flexible support layer 110, a first adhesive layer 120 located on one side of the hollow flexible support layer 110, and an ultra-thin crystalline silicon power generation layer 130 located on the side of the adhesive layer away from the hollow flexible support layer 110. The thickness of the ultra-thin crystalline silicon power generation layer 130 is less than 100 μm. The hollow area of ​​the hollow flexible support layer 110 accounts for 35% to 45%, and the hollow flexible support layer 110, the first adhesive layer 120, and the ultra-thin crystalline silicon power generation layer 130 are integrally cured and formed using a lamination process. As the base layer of the ultrathin crystalline silicon power generation layer 130, the hollow flexible support layer 110 provides support for the ultrathin crystalline silicon power generation layer 130, helps to improve its structural strength, and provides a structural basis for the bending tolerance of the solar cell module. On the other hand, the hollow structure in the hollow flexible support layer 110 introduces a controllable stress release channel, thereby reducing the overall bending stiffness of the module, so that the rollable solar cell module 100 can still maintain functional stability after multiple bending and folding.

[0034] The hollow structure in the hollow flexible support layer 110 not only modifies the module but also reduces its overall weight, which is beneficial for subsequent transportation. Furthermore, limiting the hollow area of ​​the hollow flexible support layer 110 to within the range of 35% to 45% achieves a critical balance between flexibility and mechanical support. Specifically, when the hollow area is less than 35%, the flexibility gain of the hollow flexible support layer 110 is insufficient, and the bending radius is difficult to exceed; when the hollow area is greater than 45%, the stiffness of the residual ribs in the hollow flexible support layer 110 drops sharply, causing the ultrathin crystalline silicon power generation layer 130 to easily collapse or wrinkle during lamination, which is detrimental to the subsequent use of the module; while within the 35% to 45% range, the residual ribs provide sufficient thickness-direction stiffness to the hollow flexible support layer 110, preventing local collapse or wrinkling during bending or local deformation, while also ensuring the macroscopic flexibility and uniform distribution of microscopic stress in the hollow flexible support layer 110.

[0035] In this embodiment, the thickness of the hollow flexible support layer 110 is in the range of 0.1 mm to 0.5 mm, and the hollow flexible support layer 110 can be non-uniformly hollowed out.

[0036] It should be noted that, due to the size differences of different types of battery modules, the crystalline silicon power generation layer here can be a single piece of ultra-thin crystalline silicon wafer, or it can be a battery string formed by pre-connecting multiple small-area ultra-thin crystalline silicon battery cells, and then the battery string is integrated as a whole onto the hollow flexible support layer 110.

[0037] In this embodiment, the hollow flexible support layer 110 and the ultrathin crystalline silicon power generation layer 130 are bonded together by the first adhesive layer 120, forming a pre-stacked structure. This pre-stacked structure is then integrally cured using a lamination process. The hollow flexible support layer 110, the first adhesive layer 120, and the ultrathin crystalline silicon power generation layer 130 are tightly bonded together without air bubbles, making them less prone to delamination during subsequent use.

[0038] In this embodiment, the thickness of the ultrathin crystalline silicon power generation layer 130 is in the range of 40 μm to 90 μm. Preferably, the thickness of the ultrathin crystalline silicon power generation layer 130 is 65 μm.

[0039] In this embodiment, the first adhesive layer 120 is selected from silicone, epoxy, acrylic, EVA film, and POE film. Preferably, the first adhesive layer 120 is selected from an adhesive material whose coefficient of thermal expansion is highly matched with that of the ultra-thin crystalline silicon power generation layer 130 and has excellent UV resistance and aging resistance.

[0040] In this embodiment, the hollow flexible support layer 110 is made of a material selected from composite material reinforcing fiber, flexible polymer film, metal alloy or semiconductor material.

[0041] Specifically, when the material of the hollow flexible support layer 110 is selected from composite material reinforcing fibers, the composite material reinforcing fibers are one of carbon fiber, basalt fiber, and alkali-free glass fiber; when the material of the hollow flexible support layer 110 is selected from flexible polymer films, the flexible polymer films are one of PMMA, PET, and PI; when the material of the hollow flexible support layer 110 is selected from metal alloys, the metal alloy is Kovar alloy; when the material of the hollow flexible support layer 110 is selected from semiconductor materials, the semiconductor material is an organic small molecule semiconductor or a polymer semiconductor. Preferably, the hollow flexible support layer 110 here is made of carbon fiber.

[0042] It should be noted that "semiconductor material" here refers to a thin sheet of semiconductor material with a thickness in the range of 0.1 mm to 0.5 mm.

[0043] In this embodiment, the flexible support layer 110 is made flexible through a laser-cutting process. Specifically, the laser-cutting process is a processing technique that uses a high-energy-density laser beam to locally remove material from the substrate, thereby forming a specific cutout pattern on the substrate. In the rollable solar cell module 100, this process is used to pattern the substrate of the flexible support layer 110 (such as the aforementioned composite material reinforcing fiber, flexible polymer film, or semiconductor material) to form a specific cutout structure.

[0044] In another embodiment, please refer to Figure 2 The rollable solar cell module 100 further includes a first encapsulation layer 160, a second encapsulation layer 170, a second adhesive layer 140, and a third adhesive layer 150. The first encapsulation layer 160 is located on the side of the ultrathin crystalline silicon power generation layer 130 away from the hollow flexible support layer 110, and the second encapsulation layer 170 is located on the side of the hollow flexible support layer 110 away from the ultrathin crystalline silicon power generation layer 130. The second adhesive layer 140 is located between the ultrathin crystalline silicon power generation layer 130 and the first encapsulation layer 160, and the third adhesive layer 150 is located between the hollow flexible support layer 110 and the second encapsulation layer 170.

[0045] It is easy to understand that the adhesive layers (second adhesive layer 140 and third adhesive layer 150) can be adjusted according to the actual application requirements of the product. In some cases, since the hollow flexible support layer 110 in the rollable solar cell module 100 already undertakes part of the encapsulation function, when the moisture barrier and insulation properties of the hollow flexible support layer 110 meet the actual application requirements, the adhesive layer can be set only on the side of the ultrathin crystalline silicon power generation layer 130 away from the hollow flexible support layer 110.

[0046] In this embodiment, both the second adhesive layer 140 and the third adhesive layer 150 are selected from silicone, epoxy, acrylic, EVA film, and POE film. Preferably, both the second adhesive layer 140 and the third adhesive layer 150 are selected from adhesives whose coefficient of thermal expansion is highly matched with that of the ultrathin crystalline silicon power generation layer 130 and which have outstanding UV resistance and aging resistance.

[0047] Optionally, the crystalline silicon power generation layer includes an N-type ultrathin crystalline silicon cell or a P-type ultrathin crystalline silicon cell.

[0048] Secondly, please refer to Figure 3 This invention provides a method for preparing a rollable solar cell module 100, used to prepare the aforementioned rollable solar cell module 100. The preparation method includes: S001, The substrate of the hollow flexible support layer 110 is processed by laser hollowing process to form a hollow flexible support layer 110 with a hollow area ratio of 35% to 45%. S002, a first adhesive layer 120 is coated on the surface of the hollow flexible support layer 110, and an ultrathin crystalline silicon power generation layer 130 is stacked on the side of the first adhesive layer 120 away from the hollow flexible support layer 110, and the hollow flexible support layer 110, the first adhesive layer 120 and the ultrathin crystalline silicon power generation layer 130 form a pre-stacked structure. S003, the pre-stacked structure is placed in a vacuum laminator and laminated and cured at a temperature of 80 ℃~100 ℃ to form a single unit.

[0049] A flexible support layer 110 with a specific cutout area is formed by processing the substrate using laser cutting-out technology. An ultrathin crystalline silicon power generation layer 130 is then integrated onto the flexible support layer 110 via a first adhesive layer 120, forming a pre-stacked structure. This pre-stacked structure is then integrally cured using a lamination process. The flexible support layer 110, the first adhesive layer 120, and the ultrathin crystalline silicon power generation layer 130 are tightly bonded together without air bubbles, making them less prone to delamination during subsequent use.

[0050] In summary, the rollable solar cell module 100 provided in this embodiment of the invention integrates the ultrathin crystalline silicon power generation layer 130 onto the hollow flexible support layer 110 through the first adhesive layer 120, and controls the hollow area ratio of the hollow flexible support layer 110 within the range of 35% to 45%. The hollow flexible support layer 110, with its hollow area ratio controlled at 35% to 45%, provides support for the ultrathin crystalline silicon power generation layer 130, helping to improve its structural strength and providing a structural basis for the rollability tolerance of the rollable solar cell module 100. Furthermore, the hollow structure in the hollow flexible support layer 110 introduces controllable stress release channels, thereby reducing the overall bending stiffness of the module, enabling the rollable solar cell module 100 to maintain functional stability after multiple rolls and bends, and adapting to curved surface installation scenarios.

[0051] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A rollable solar cell module, characterized in that, include: Hollowed-out flexible support layer; The first adhesive layer is located on one side of the hollow flexible support layer; And an ultra-thin crystalline silicon power generation layer located on the side of the adhesive layer away from the hollow flexible support layer, wherein the thickness of the ultra-thin crystalline silicon power generation layer is less than 100 μm; The hollow area of ​​the hollow flexible support layer accounts for 35% to 45%, and the hollow flexible support layer, the adhesive layer and the crystalline silicon power generation layer are integrally cured and formed by lamination process.

2. The rollable solar cell module according to claim 1, characterized in that, The thickness of the hollow flexible support layer is in the range of 0.1 mm to 0.5 mm.

3. The rollable solar cell module according to claim 1, characterized in that, The thickness of the ultrathin crystalline silicon power generation layer is in the range of 40 μm to 90 μm.

4. The rollable solar cell module according to claim 1, characterized in that, The rollable solar cell module further includes a first encapsulation layer and a second encapsulation layer, wherein the first encapsulation layer is located on the side of the crystalline silicon power generation layer away from the hollow flexible support layer, and the second encapsulation layer is located on the side of the hollow flexible support layer away from the crystalline silicon power generation layer. The rollable solar cell module further includes a second adhesive layer and a third adhesive layer, wherein the second adhesive layer is located between the ultrathin crystalline silicon power generation layer and the first encapsulation layer, and the third adhesive layer is located between the hollow flexible support layer and the second encapsulation layer.

5. The rollable solar cell module according to claim 4, characterized in that, The first adhesive layer, the second adhesive layer, and the third adhesive layer are all selected from one of silicone, epoxy, acrylic, EVA film, and POE film.

6. The rollable solar cell module according to claim 1, characterized in that, The crystalline silicon power generation layer includes N-type ultrathin crystalline silicon solar cells or P-type ultrathin crystalline silicon solar cells.

7. The rollable solar cell module according to claim 1, characterized in that, The hollow flexible support layer is made of a material selected from composite reinforcing fibers, flexible polymer films, metal alloys, or semiconductor materials.

8. The rollable solar cell module according to claim 7, characterized in that, The hollow flexible support layer is made of one of the following materials: carbon fiber, basalt fiber, and alkali-free glass fiber.

9. The rollable solar cell module according to claim 7, characterized in that, The hollow flexible support layer is made of one of PMMA, PET, or PI.

10. The rollable solar cell module according to any one of claims 7 to 9, characterized in that, The flexible support layer is made flexible through laser hollowing process.

11. A method for preparing a rollable solar cell module, used to prepare the rollable solar cell module according to any one of claims 1 to 10, characterized in that, include: S001, The substrate of the hollow flexible support layer is processed by laser hollowing process to form the hollow flexible support layer with a hollow area ratio of 35% to 45%. S002, A first adhesive layer is coated on the surface of the hollow flexible support layer, and an ultrathin crystalline silicon power generation layer is stacked on the side of the first adhesive layer away from the hollow flexible support layer, wherein the hollow flexible support layer, the first adhesive layer and the ultrathin crystalline silicon power generation layer form a pre-stacked structure. S003, The pre-stacked structure is placed in a vacuum laminator and laminated and cured at a temperature of 80-100℃ to form a single unit.

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