Lightweight flexible photovoltaic module

Abstract

The utility model relates to the technical field of photovoltaic modules, and discloses a light flexible photovoltaic module. The light flexible photovoltaic module comprises a weather-proof front plate film, a first packaging adhesive film, a flexible reinforcing material layer, a second packaging adhesive film, a photovoltaic battery piece, a third packaging adhesive film and a photovoltaic back plate which are sequentially laminated from top to bottom, the weather-proof front plate film comprises a transparent base material, the upper surface and the lower surface of the transparent base material are provided with an outer weather-proof layer and a water vapor blocking layer respectively, and the lower surface of the water vapor blocking layer is further provided with an inner bonding layer used for bonding the first packaging adhesive film. The light flexible photovoltaic module is simple in structure, low in cost, good in water vapor barrier property, impact resistance, mechanical strength, weather resistance and aging resistance, good in adhesiveness with packaging adhesive films such as EVA, good in light transmittance and the like, capable of reducing power attenuation after light flexible photovoltaic UV aging and UV damp-heat aging and capable of improving the service life of the light flexible photovoltaic module. And the hail resistance and the outdoor service life of the light flexible photovoltaic module are improved.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module technology, specifically to a lightweight flexible photovoltaic module. Background Technology

[0002] With the rapid rise of distributed photovoltaic power stations, lightweight flexible photovoltaic modules have gained market favor due to their lightweight, ease of installation and transportation, strong adaptability, and ability to conform to various curved surfaces. However, traditional lightweight flexible photovoltaic modules have significant shortcomings in mechanical strength, high temperature resistance, weather resistance, and water vapor barrier properties. This not only limits the service life of lightweight flexible photovoltaic modules but also restricts the expansion of their application scenarios.

[0003] Based on this, CN116759478A discloses a lightweight photovoltaic module, which includes a front panel layer, a front encapsulant layer, a cell layer, a rear encapsulant layer, and a rear panel layer stacked sequentially on their surfaces. The front panel layer, from the outside to the inside, includes an anti-UV fluorine film layer, an adhesive layer, a transparent support layer, a glass fiber transparent resin reinforcement layer, and an adhesive layer. The anti-UV fluorine film layer has a multi-layer structure, including an anti-UV barrier layer in the core layer and fluorine film surface layers on both sides. The rear panel layer includes a thermosetting resin fiber reinforced composite material support layer and functional layers on both sides. Through the cooperation of the front and rear panel layers, this lightweight photovoltaic module possesses the characteristics of being lightweight, highly efficient, impact-resistant, and having long-term reliability. However, the front panel of this lightweight photovoltaic module has a complex structure with seven layers stacked from the outside to the inside: a fluorine film surface layer, an anti-ultraviolet barrier layer, another fluorine film surface layer, an adhesive layer, a transparent support layer, a glass fiber transparent resin reinforcement layer, and an adhesive layer. This structure is relatively expensive. Moreover, the front panel of this lightweight photovoltaic module lacks a moisture barrier layer, resulting in poor moisture barrier performance. Moisture can easily enter the encapsulation film, generating acetic acid which then etches the solar cells, causing power degradation in the module.

[0004] Furthermore, CN208674142U discloses a flexible photovoltaic module, which includes an integrated front panel, flexible cell strings, a sealing device, and an integrated back panel. The integrated front panel includes a front panel weather-resistant layer, a first adhesive layer, a front panel water-blocking layer, a second adhesive layer, a front panel insulating layer, and a front panel encapsulating film, all stacked together. The integrated back panel also includes a back panel weather-resistant layer, a third adhesive layer, a back panel water-blocking layer, a fourth adhesive layer, a back panel insulating layer, and a back panel encapsulating film, all stacked together. Although this flexible photovoltaic module adds a water-blocking layer, providing better water vapor barrier performance, its layered structure is extremely complex and costly. Furthermore, its impact resistance and mechanical strength are poor, its hail resistance is limited, and its outdoor lifespan is short, still making it prone to power degradation. Utility Model Content

[0005] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a lightweight and flexible photovoltaic module.

[0006] Based on this, the present invention discloses a lightweight flexible photovoltaic module, comprising, from top to bottom, a weather-resistant front sheet film, a first encapsulating film, a flexible reinforcing material layer, a second encapsulating film, a photovoltaic cell, a third encapsulating film, and a photovoltaic backsheet.

[0007] The weather-resistant front panel film includes a transparent substrate. The upper and lower surfaces of the transparent substrate are respectively provided with an outer weather-resistant layer and a moisture barrier layer. The lower surface of the moisture barrier layer is also provided with an inner adhesive layer for bonding the first encapsulating film.

[0008] Preferably, the outer weather-resistant layer is a hydrophobic weather-resistant coating with a thickness of 10-30 μm.

[0009] More preferably, the outer weather-resistant layer is a fluorosilicone modified polyester weather-resistant coating or a fluorosilicone weather-resistant coating, with a thickness of 18-25 μm.

[0010] Preferably, the transparent substrate is a heat-resistant transparent polyester film with a thickness of 20-75 μm.

[0011] More preferably, the transparent substrate is a polyethylene terephthalate (PET) film with a thickness of 45-55 μm.

[0012] Preferably, the water vapor barrier layer is a water-blocking coating with a thickness of 10-100 nm.

[0013] More preferably, the water vapor barrier layer is a silicon dioxide water-blocking coating with a thickness of 50-100 nm (more preferably 80-100 nm).

[0014] Preferably, the inner adhesive layer is an adhesive coating, which is a polyacrylate coating, a polyester coating, or a polyacrylate-modified polyester coating; the thickness of the inner adhesive layer is 8-15 μm (preferably 10-12 μm).

[0015] Preferably, the flexible reinforcing material layer comprises a glass fiber mesh structure and an organic polymer material layer filling the mesh openings and surface of the glass fiber mesh structure;

[0016] The organic polymer material layer is an organosilicon-modified polyurethane material layer (such as a polysiloxane-modified polyurethane material layer), and the basis weight of the glass fiber is 100-300 g / m². 2 (e.g., 100g / m 2 160g / m 2 210g / m 2 Or 300g / m2 The preferred basis weight of glass fiber is 300 g / m². 2 The thickness of the flexible reinforcing material layer is 130-400 μm.

[0017] In this flexible reinforcement material layer, the silanol groups of polysiloxane in the organic polymer material layer can participate in the reaction during the heating and lamination of the lightweight flexible photovoltaic module, thereby improving the adhesion performance between the flexible reinforcement material layer and encapsulation films such as EVA.

[0018] Preferably, the upper surface of the weather-resistant front film has an embossed morphology. This embossed morphology acts as a light trap, enhancing the ability of light to enter the lightweight flexible photovoltaic module, thereby increasing power generation and making the lightweight flexible photovoltaic module more impact-resistant and durable.

[0019] With all improvements, this utility model not only enhances the overall performance and reliability of lightweight flexible photovoltaic modules, but also reduces their long-term maintenance costs and improves energy output efficiency, thus playing a positive role in promoting the popularization and development of distributed photovoltaic power stations.

[0020] Compared with the prior art, the present invention has at least the following beneficial effects:

[0021] This invention discloses a lightweight flexible photovoltaic module equipped with a weather-resistant front sheet film. This film, through the combination of an outer weather-resistant layer, a transparent substrate, a moisture barrier layer, and an inner adhesive layer, helps improve its moisture barrier performance, resistance to yellowing after UV aging and UV damp heat aging, adhesion to encapsulating films such as EVA, and light transmittance, thereby helping to reduce power degradation after aging. Furthermore, this invention also incorporates a flexible reinforcing material layer, which helps improve the impact resistance and mechanical strength of the weather-resistant front sheet film, further reducing power degradation after damp heat aging and hail tests, ensuring stable operation in extreme environments.

[0022] Therefore, compared with existing lightweight flexible photovoltaic modules, the lightweight flexible photovoltaic module of this invention, with a weather-resistant front sheet film, a flexible reinforcing material layer, and two encapsulation films (i.e., a first encapsulation film and a second encapsulation film) on top of the photovoltaic cells, has higher water vapor barrier performance, impact resistance, mechanical strength, weather resistance and aging resistance (such as resistance to yellowing after UV aging and UV damp heat aging), and adhesion to encapsulation films such as EVA. Furthermore, this lightweight flexible photovoltaic module has a stable structure and high flexibility, which can greatly reduce the power attenuation of the lightweight flexible photovoltaic module after damp heat aging and after hail resistance tests, thus improving the hail resistance and outdoor service life of the lightweight flexible photovoltaic module. Moreover, compared with existing lightweight flexible photovoltaic modules such as CN116759478A and CN208674142U, the lightweight flexible photovoltaic module of this invention has a simpler structure and lower production cost. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the cross-sectional structure of a lightweight flexible photovoltaic module in Embodiment 1.

[0024] Figure 2 This is a schematic diagram of the cross-sectional structure of the weather-resistant front plate membrane in Embodiment 1.

[0025] Figure 3 This is a schematic diagram of the flexible reinforcing material layer in this embodiment 1.

[0026] Explanation of reference numerals: 1. Weather-resistant front sheet film; 11. Outer weather-resistant layer; 12. Transparent substrate; 13. Moisture barrier layer; 14. Inner adhesive layer; 2. First encapsulating film; 3. Flexible reinforcing material layer; 31. Organic polymer material layer; 32. Glass fiber mesh structure; 4. Second encapsulating film; 5. Photovoltaic cell; 6. Third encapsulating film; 7. Photovoltaic backsheet. Detailed Implementation

[0027] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] Example

[0029] This embodiment describes a lightweight, flexible photovoltaic module, see [link to example]. Figure 1-2 The module comprises, from top to bottom, a weather-resistant front sheet film 1, a first encapsulating film 2, a flexible reinforcing material layer 3, a second encapsulating film 4, a photovoltaic cell 5, a third encapsulating film 6, and a photovoltaic backsheet 7 (such as a reinforced backsheet). In this lightweight flexible photovoltaic module, the upper surface refers to the light-facing surface of the module, while the lower surface refers to the backlighting surface.

[0030] See Figure 2The weather-resistant front sheet film 1 includes an outer weather-resistant layer 11, a transparent substrate 12, a moisture barrier layer 13, and an inner adhesive layer 14, which are stacked sequentially from top to bottom. The inner adhesive layer 14 of the weather-resistant front sheet film 1 is bonded to the light-facing side of the photovoltaic cell 5 by an encapsulating film (such as the first encapsulating film 2).

[0031] The outer weather-resistant layer 11 is a hydrophobic weather-resistant coating with a thickness of 10-30 μm (e.g., 10 μm, 15 μm, 18 μm, 20 μm, 25 μm, 28 μm, or 30 μm). This hydrophobic weather-resistant coating has strong hydrophobic properties, which can effectively prevent whitening caused by the resin easily absorbing water when the ambient humidity is high, and also helps to improve the UV (ultraviolet) aging and yellowing resistance of the weather-resistant film 1 after UV damp heat aging.

[0032] Furthermore, the outer weather-resistant layer 11 is preferably a fluorosilicone modified polyester weather-resistant coating or a fluorosilicone weather-resistant coating, and its thickness is preferably 18-25μm (e.g., 20μm).

[0033] Furthermore, the upper surface of the outer weathering layer 11 of the weathering front film 1 in this embodiment also has an embossed morphology. This embossed morphology has a light trapping effect, enhancing the ability of light to enter the lightweight flexible photovoltaic module, improving power generation, and making the lightweight flexible photovoltaic module more impact-resistant, thereby improving the durability of the lightweight flexible photovoltaic module.

[0034] Among them, the transparent substrate 12 is a heat-resistant transparent polyester film with a thickness of 20-75μm (such as 20μm, 30μm, 45μm, 50μm, 55μm, 60μm, 70μm or 75μm).

[0035] Specifically, the transparent substrate 12 is preferably a polyethylene terephthalate (PET) film, with a thickness preferably of 45-55 μm (e.g., 50 μm). The temperature resistance of the PET film is preferably 150-200°C to balance the adhesion and deformation risk during processing.

[0036] The water vapor barrier layer 13 is a water-blocking coating with a thickness of 10-100nm (e.g., 10nm, 30nm, 50nm, 60nm, 70nm, 80nm, 90nm, or 100nm). In this embodiment, the weather-resistant front film 1 is combined with the water vapor barrier layer 13, which enhances its water-blocking performance and effectively prevents water vapor from entering the encapsulation film and generating acetic acid, which would then corrode the solar cells. This helps to reduce the power degradation of lightweight flexible photovoltaic modules after damp heat aging.

[0037] Furthermore, the water vapor barrier layer 13 is preferably a silicon dioxide water-blocking coating, and its thickness is preferably 50-100 nm (more preferably 80-100 nm).

[0038] The inner adhesive layer 14 is an adhesive coating, which is a polyacrylate coating, a polyester coating, or a polyacrylate-modified polyester coating; the thickness of the inner adhesive layer 14 is 8-15 μm (preferably 10-12 μm). In this embodiment, the weather-resistant front panel film 1 also uses the above-mentioned inner adhesive layer 14, which can protect the moisture barrier layer 13 (the moisture barrier layer 13 is very thin and easily scratched); moreover, the inner adhesive layer 14 can also improve the adhesion between the weather-resistant front panel film 1 and the encapsulating film such as EVA.

[0039] Therefore, the weather-resistant front panel film 1 used in this embodiment, through the combination of the outer weather-resistant layer 11, transparent substrate 12, water vapor barrier layer 13 and inner adhesive layer 14, helps to improve its water vapor barrier performance, yellowing resistance after UV aging and UV damp heat aging, adhesion to encapsulation films such as EVA, impact resistance, light transmittance, etc., thereby helping to reduce the power decay of lightweight flexible photovoltaic modules after aging.

[0040] The flexible reinforcing material layer 3 includes a glass fiber mesh structure 32 and an organic polymer material layer 31 (such as...) filling the mesh openings of the glass fiber mesh structure 32 and the surface of the glass fiber mesh structure 32. Figure 3 (As shown).

[0041] Preferably, the organic polymer material layer 31 is an organosilicon-modified polyurethane material layer (such as a polysiloxane-modified polyurethane material layer), and the basis weight of the glass fiber is 100-300 g / m². 2 (e.g., 100g / m 2 160g / m 2 210g / m 2 Or 300g / m 2 Preferably 300g / m 2 The thickness of the flexible reinforcing material layer 3 is 130-400 μm (e.g., 130 μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, or 400 μm). In this flexible reinforcing material layer 3, the silanol groups of the polysiloxane in the organic polymer material layer 31 can participate in the reaction during the heat lamination of the lightweight flexible photovoltaic module, thus helping to improve the adhesion performance between the flexible reinforcing material layer 3 and encapsulating films such as EVA.

[0042] The lightweight flexible photovoltaic module of this embodiment is also used in conjunction with the aforementioned flexible reinforcing material layer 3. The flexible reinforcing material layer 3 is stacked between the first encapsulating film 2 and the second encapsulating film 4 of the lightweight flexible photovoltaic module. It can enhance the mechanical properties of the lightweight flexible photovoltaic module, protect the lightweight flexible photovoltaic module, and resist high temperature. Moreover, the flexible reinforcing material layer 3 has good adhesion to encapsulating films such as EVA, which helps to reduce the power attenuation of the lightweight flexible photovoltaic module after damp heat aging and improve its hail resistance, thus ensuring its stable operation in extreme environments.

[0043] This embodiment of a method for manufacturing a lightweight flexible photovoltaic module includes the following manufacturing steps:

[0044] S1. Fabrication of weather-resistant front sheet film 1:

[0045] S11. The transparent substrate 12 is subjected to plasma cleaning to remove organic matter and dust, and then a water vapor barrier layer 13 is prepared on the lower surface of the transparent substrate 12.

[0046] S12. Apply the hydrophobic weather-resistant coating to the upper surface of the transparent substrate 12 and cure it to form a hydrophobic weather-resistant coating (i.e., the outer weather-resistant layer 11).

[0047] S13. An inner adhesive layer 14 is prepared on the lower surface of the water vapor barrier layer 13.

[0048] S2. Fabrication of Flexible Reinforcing Material Layer 3: The glass fiber mesh structure 32 is fully impregnated with an organic polymer material as an impregnation liquid. After coating and thickness control, it is placed in an oven and cured to obtain the flexible reinforcing material layer 3. Alternatively, existing finished flexible reinforcing material layers 3 can be used in practice.

[0049] S3. The weather-resistant front sheet film 1, the first encapsulating film 2, the flexible reinforcing material layer 3, the second encapsulating film 4, the photovoltaic cell 5, the third encapsulating film 6, and the photovoltaic back sheet 7 are stacked sequentially from top to bottom, and then heated and laminated to obtain the lightweight flexible photovoltaic module.

[0050] In step S3, during the heating and lamination process, the upper surface of the weather-resistant front film 1 is embossed (e.g., embossed with embossed cloth) to form an embossed morphology.

[0051] Compared to existing lightweight flexible photovoltaic modules, the lightweight flexible photovoltaic module of this embodiment incorporates a weather-resistant front sheet film 1, a flexible reinforcing material layer 3, and two encapsulation films (i.e., the first encapsulation film 2 and the second encapsulation film 4) above the photovoltaic cell 5. This results in superior performance in terms of water vapor barrier properties, impact resistance, mechanical strength, weather resistance and aging resistance (such as resistance to yellowing after UV aging and UV damp heat aging), and adhesion to encapsulation films such as EVA. Furthermore, this lightweight flexible photovoltaic module exhibits stable structure and high flexibility, significantly reducing power attenuation after damp heat aging and hail resistance tests. Therefore, it improves hail resistance and outdoor lifespan. Moreover, compared to existing lightweight flexible photovoltaic modules such as CN116759478A and CN208674142U, the lightweight flexible photovoltaic module of this invention has a simpler structure and lower production costs.

[0052] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0053] The technical solution provided by this utility model has been described in detail above. Specific examples have been used to illustrate the principle and implementation of this utility model. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​this utility model. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A lightweight flexible photovoltaic module, characterized by, It includes, from top to bottom, a weather-resistant front sheet film, a first encapsulating film, a flexible reinforcing material layer, a second encapsulating film, a photovoltaic cell, a third encapsulating film, and a photovoltaic backsheet, which are stacked in sequence. The weather-resistant front panel film includes a transparent substrate. The upper and lower surfaces of the transparent substrate are respectively provided with an outer weather-resistant layer and a moisture barrier layer. The lower surface of the moisture barrier layer is also provided with an inner adhesive layer for bonding the first encapsulating film.

2. A lightweight flexible photovoltaic module according to claim 1, wherein, The outer weather-resistant layer is a hydrophobic weather-resistant coating with a thickness of 10-30 μm.

3. A lightweight flexible photovoltaic module according to claim 1 or 2, characterised in that, The outer weather-resistant layer is a fluorosilicone modified polyester weather-resistant coating or a fluorosilicone weather-resistant coating, with a thickness of 18-25 μm.

4. A lightweight flexible photovoltaic assembly according to claim 1, wherein, The transparent substrate is a heat-resistant transparent polyester film with a thickness of 20-75μm.

5. A lightweight flexible photovoltaic module according to claim 1 or 4, characterized in that, The transparent substrate is a polyethylene terephthalate (PET) film with a thickness of 45-55 μm.

6. A lightweight flexible photovoltaic assembly according to claim 1, wherein, The water vapor barrier layer is a water-blocking coating with a thickness of 10-100 nm.

7. A lightweight flexible photovoltaic module according to claim 1 or 6, wherein, The water vapor barrier layer is a silicon oxide water-blocking coating with a thickness of 50-100 nm.

8. A lightweight flexible photovoltaic assembly according to claim 1, wherein, The inner adhesive layer is an adhesive coating, which is a polyacrylate coating, a polyester coating, or a polyacrylate-modified polyester coating; the thickness of the inner adhesive layer is 8-15 μm.

9. A lightweight flexible photovoltaic assembly according to claim 1, wherein, The flexible reinforcing material layer includes a glass fiber mesh structure and an organic polymer material layer filling the mesh pores of the glass fiber mesh structure and the surface of the glass fiber mesh structure. The organic polymer material layer is a layer of silicone-modified polyurethane material, and the glass fiber has a grammage of 100-300 g / m 2 ; The thickness of the flexible reinforcing material layer is 130-400 μm.

10. A lightweight flexible photovoltaic assembly according to claim 1, wherein, The upper surface of the weather-resistant front panel film has an embossed morphology.

Images