A functional film, photovoltaic module and display device

Abstract

The application discloses a functional film, a photovoltaic module and a display device, and is applied to the technical field of optical devices.The functional film comprises a first carrier layer and at least one second carrier layer, the first carrier layer is transparent at least in an optical functional area thereof, and at least one first surface structure is arranged on the surface of the first carrier layer; the second carrier layer is fixedly combined with the first carrier layer, at least one first cavity with an optical function is formed between the first surface structure of the first carrier layer and the second carrier layer; the first cavity is communicated with the external environment of the functional film through at least one open channel; the open channel has at least one opening, and the normal direction of the opening plane of the opening is arranged as a horizontal plane or a first preset angle with the horizontal plane.The functional film in the application optimizes the design of the cavity, improves the utilization rate of light, reduces the stress loss, enhances the stability of the overall structure, and reduces the risk of panel explosion.

Description

Technical Field

[0001] This application relates to the field of optical device technology, and in particular to a functional film, photovoltaic module and display device. Background Technology

[0002] With the rapid development of technology, optical functional thin films, due to their ability to improve device performance, reliability, and durability, are increasingly being used in various fields, such as semiconductor manufacturing, displays, and solar cells. In the field of solar cells, the application of optical functional thin films is particularly extensive, not only helping to maintain the stability and functionality of the cell structure but also playing a role in improving cell efficiency and extending lifespan. As solar cells continuously pursue higher performance standards, the requirements for gap-enhancing films in optical functional thin films are also becoming increasingly stringent. Therefore, research on functional films is particularly important in order to improve light utilization.

[0003] Currently, one approach to functional films in related technologies is to use traditional enamel-coated glass, but this approach has low reflectivity and a high rate of plate breakage. Another approach is to use a closed-loop laminated structure. This structure achieves optical performance through the difference in refractive index between the substrate of the double-layer structure and the optical cavity enclosed between the double-layer structure. However, the manufacturing process of this laminated structure has high requirements for airtightness, and due to the airtightness of the cavity, there are problems such as reduced product life or risk of plate breakage due to thermal stress, inability to remove solvents or moisture that may remain from the manufacturing process, irreparable damage once internal contamination occurs, and unsuitability for certain applications that require specific interaction with the outside world (such as specific gas sensing). Utility Model Content

[0004] The purpose of this application is to provide a functional membrane that optimizes the cavity design, improves light utilization, reduces stress loss, enhances the stability of the overall structure, and reduces the risk of plate bursting.

[0005] To achieve the above objectives, this application provides the following solution:

[0006] In a first aspect, this application provides a functional film for use inside a photovoltaic module or a display device, the functional film comprising at least two carrier layers, the at least two carrier layers comprising:

[0007] A first carrier layer, wherein the first carrier layer is transparent at least in its optical functional area, and at least one first surface structure is provided on its surface.

[0008] At least one second carrier layer is fixedly bonded to the first carrier layer, forming at least one first cavity with optical function between the first surface structure of the first carrier layer and the second carrier layer; wherein the first cavity communicates with the external environment of the functional membrane through at least one opening channel, the opening channel being defined by the structure of the first carrier layer, the second carrier layer, or a combination thereof; and the opening channel having at least one opening, the normal direction of the opening plane being set at a horizontal plane or at a first preset angle to the horizontal plane.

[0009] Optionally, the functional membrane includes at least a first set of cavities and a second set of cavities, the first set of cavities extending along a first direction and the second set of cavities extending along a second direction, wherein both the first direction and the second direction are perpendicular to the thickness direction of the functional membrane, and the first direction and the second direction form a second preset angle.

[0010] Optionally, the surface of the at least one second carrier layer is provided with at least one second surface structure to form at least one second cavity between the second carrier layer and the first carrier layer; and the first set of cavities is formed by the first surface structure, and the second set of cavities is formed by at least one second surface structure.

[0011] Optionally, at least one cavity in the first group of cavities is interconnected with at least one cavity in the second group of cavities to form a three-dimensional open cavity network.

[0012] Optionally, at least one of the openings or the opening channel is provided with a self-cleaning layer or microgrid.

[0013] Optionally, the second carrier layer includes at least one reflective component having at least one reflective surface facing the first carrier layer.

[0014] Optionally, the first carrier layer and / or the second carrier layer may contain a thermally conductive material to improve the thermal conductivity of the functional membrane.

[0015] Secondly, this application provides a photovoltaic module, including the functional film and solar cell provided in the above embodiments, wherein the functional film is located on the surface of the solar cell, between two solar cells, and between the solar cell and the module frame.

[0016] Thirdly, this application provides a display device, including a functional film and a glass substrate as provided in the above embodiments, wherein the functional film is located between two glass substrates or between a glass substrate and a device frame.

[0017] According to the specific embodiments provided in this application, the following technical effects are disclosed:

[0018] This application provides a functional film, a photovoltaic module, and a display device. The functional film includes at least two carrier layers, each including a first carrier layer and at least one second carrier layer. The first carrier layer is transparent at least in its optical functional area and has at least one first surface structure on its surface. The second carrier layer is fixedly bonded to the first carrier layer, forming at least one optically functional first cavity between the first surface structure of the first carrier layer and the second carrier layer. The first cavity communicates with the external environment of the functional film through at least one opening channel, which is defined by the structure of the first carrier layer, the second carrier layer, or a combination thereof. The opening channel has at least one opening, and the normal direction of the opening plane is either horizontal or at a first predetermined angle to the horizontal plane. Compared with the prior art, the functional film of this application achieves internal pressure self-balancing through its open cavity structure, avoiding the accumulation of internal thermal stress caused by temperature changes. This reduces the risk of lamination delamination or module bursting, enhances the long-term weather resistance of the product, and significantly improves structural reliability. Furthermore, it combines openness with anti-contamination capabilities: thanks to its structural design where the opening normal direction does not face upwards, and optionally combined with a self-cleaning layer or microgrid, it achieves effective defense against external contaminants while possessing the advantages of open channels (such as pressure equalization and moisture dissipation); and its multi-layered, multi-directional cavity network design breaks the limitations of two-dimensional planar structures, providing a new design platform for achieving multi-dimensional fine control of the light field, or for customizing specific directional flexibility and stiffness mechanical properties for flexible and foldable devices; it can expand functional integration and application modes, conveniently integrating reflective, thermally conductive and other functional materials, transforming functional films from single optical transmission / guiding elements into platform devices that can achieve composite functions such as high-efficiency reflection and thermal management, and since it does not require absolute hermetic sealing of the cavity, it is expected to simplify the stringent requirements of manufacturing processes such as lamination, which will help improve production yield and reduce costs. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of a functional membrane provided in an embodiment of this application;

[0021] Figure 2 This is a schematic diagram of the structure of a functional membrane provided in another embodiment of this application;

[0022] Figure 3A top view of the functional membrane provided in the embodiments of this application;

[0023] Figure 4 This is a schematic diagram of the structure of a functional membrane provided in another embodiment of this application;

[0024] Figure 5 This is a schematic diagram of the structure of a functional membrane provided in another embodiment of this application;

[0025] Figure 6 A schematic diagram of the structure of the first carrier layer provided in the embodiments of this application;

[0026] Figure 7 This is a schematic diagram of the structure of the second carrier layer provided in an embodiment of this application;

[0027] Figure 8 A schematic flowchart illustrating the manufacturing method of the functional membrane provided in this application embodiment;

[0028] Explanation of reference numerals in the attached figures:

[0029] First carrier layer-10; First cavity-11; First cavity opening channel-13; Second carrier layer-20; Second cavity-21; Second cavity opening channel-23. Detailed Implementation

[0030] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0031] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] As mentioned in the background section, one approach in related technologies is to use traditional enamel-coated glass, but this solution has low reflection efficiency and a high rate of glass breakage. Another approach is to use a laminated structure to achieve cavity sealing. In this laminated structure, the difference in refractive index between the substrate of the double-layer structure and the optical cavity achieves optical performance. However, the manufacturing process of this laminated structure is demanding, and due to the sealing of the cavity, there are problems such as reduced product lifespan or risk of glass breakage caused by thermal stress, inability to remove solvents or moisture that may remain during the manufacturing process, irreparable damage once internal contamination occurs, and unsuitability for certain applications that require specific interaction with the outside world (such as specific gas sensing).

[0033] Based on the above-mentioned deficiencies, this application provides a functional membrane. Compared with the prior art, the functional membrane of this application achieves internal pressure self-balancing through its open cavity structure, avoiding the accumulation of internal thermal stress caused by temperature changes, thereby reducing the risk of delamination of laminated structures or component bursting, enhancing the long-term weather resistance of the product, and significantly improving structural reliability. Furthermore, it combines openness with anti-contamination capabilities: thanks to its structural design where the opening normal direction does not face upwards, and optionally combined with a self-cleaning layer or microgrid, it achieves effective defense against external contaminants while possessing the advantages of open channels (such as pressure equalization and moisture dissipation); and its multi-layered, multi-directional cavity network design breaks the limitations of two-dimensional planar structures, providing a new design platform for achieving multi-dimensional fine control of the light field, or for customizing specific directional flexibility and stiffness mechanical properties for flexible and foldable devices; it can expand functional integration and application modes, conveniently integrating reflective, thermally conductive and other functional materials, transforming functional films from single optical transmission / guiding elements into platform devices that can achieve composite functions such as high-efficiency reflection and thermal management, and since it does not require absolute hermetic sealing of the cavity, it is expected to simplify the stringent requirements of manufacturing processes such as lamination, which will help improve production yield and reduce costs.

[0034] Please see Figure 1 As shown, Figure 1 This is a schematic diagram of the structure of the functional film provided in the embodiments of this application. The functional film is applied inside a photovoltaic module or a display device. The functional film includes at least two light-transmitting carrier layers, which include a first carrier layer 10 and at least one second carrier layer 20. The first carrier layer 10 is light-transmitting at least in its optical functional area, and at least one first surface structure is provided on its surface. The second carrier layer 20 is fixedly combined with the first carrier layer, and at least one optically functional first cavity 11 is formed between the first surface structure of the first carrier layer 10 and the second carrier layer 20. The first cavity 11 communicates with the external environment of the functional film through at least one opening channel, which is defined by the structure of the first carrier layer 10, the second carrier layer 20, or a combination thereof. The opening channel has at least one opening, and the normal direction of the opening plane is set at a horizontal plane or at a first preset angle to the horizontal plane.

[0035] It should be noted that the aforementioned at least two carrier layers can be two carrier layers, or three or more carrier layers. The optical functional area of ​​the first carrier layer is transparent, while the non-optical functional area can be transparent or opaque. The transparent material can include transparent polymer films, plastics, glass sheets, silicon-based materials, or other materials with high light transmittance. The transparent polymer film can include optical-grade polyethylene terephthalate (PET), cyclic olefin copolymers (COC), PMMA, PC, etc. The fixing connection between the first carrier layer and the second carrier layer can be selected as a thermosetting fixing connection or an adhesive fixing connection. The functional film provided in this embodiment, by setting a carrier layer with transparent functional areas, allows light to pass through, making it suitable for various photovoltaic modules or display modules. The photovoltaic module can include solar cells, and the display module can include liquid crystal displays, OLED displays, etc.

[0036] The aforementioned first surface structure is disposed on the surface of the first carrier layer, and at least one first cavity is formed between the first surface structure and the second carrier layer for realizing a specific optical function. The optical function may include, but is not limited to, light refraction, focusing, guiding, reflection, diffraction, etc. The optical function of each first cavity may be set according to its cavity size, dimensions and material.

[0037] On the surface of the first carrier layer, at least one first cavity with optical functions can be formed using precision micro-nano fabrication techniques, such as photolithography, etching, or molding. Optionally, the first cavity can have a regular or irregular geometric shape, such as a triangular cavity, hexagonal cavity, curved cavity, trapezoidal cavity, cylindrical cavity, conical or frustum-shaped cavity, etc. The shape of the first cavity is not limited in this embodiment. The inner surface of the first cavity can be specially coated to achieve optical functions such as light reflection, refraction, diffraction, or interference, for example, by enhancing the transmittance or reflectance of light of a specific wavelength through the interference effect of multilayer dielectric films. The size and shape of the opening channel of the first cavity can be customized according to the size of the first cavity to ensure efficient light transmission.

[0038] The aforementioned opening channel is defined by a structure consisting of a first carrier layer, a second carrier layer, or a combination thereof, and includes: the opening channel being entirely formed on the first carrier layer, for example, a groove on the first carrier layer extending to the edge of the membrane; the opening channel being entirely formed on the second carrier layer, for example, a through-hole or groove on the second carrier layer aligned with the first cavity; or the opening channel being jointly formed by the structures of the first and second carrier layers, for example, a groove in the first carrier layer and a groove in the second carrier layer aligning to form a complete channel. An opening channel refers to a channel with at least one opening that connects the first cavity to the external environment of the functional membrane. The normal direction of the opening plane is either horizontal or at a first predetermined angle to the horizontal plane, meaning the normal direction of the opening plane does not have an upward vertical component, including a horizontal normal, a downwardly angled normal, or a vertically downward normal.

[0039] The aforementioned first carrier layer is connected to the second carrier layer through a first surface structure. This unique three-dimensional structure breaks the limitations of traditional planar film layers, creating more path options for light propagation and effectively controlling the direction and distribution of light propagation. Specifically, the first cavity has at least one first cavity opening channel, which has at least one opening. The normal direction of the opening plane is set to the horizontal plane or at a first preset angle to the horizontal plane. This first preset angle can be flexibly adjusted within the range of 0°-90° according to actual application requirements. For example, it can be perpendicular to or nearly perpendicular to the horizontal plane, meaning the first preset angle can be equal to or nearly right-angled.

[0040] The above Figure 1 In the first carrier layer 10, there is a first cavity 11 that extends in a first direction, and the first cavity 11 includes a first cavity opening channel 13. The second carrier layer 20 is a solid layer structure.

[0041] In addition, the multiple carrier layer structure of the functional film can also have good physical support and isolation properties. In photovoltaic modules, it can effectively prevent the internal structure from being damaged by external pressure. In display devices, it can provide a stable working environment for the liquid crystal layer or organic light-emitting layer, thereby improving the reliability and service life of the product.

[0042] The second carrier layer may include functional and non-functional areas. The functional area of ​​the second carrier layer may be transparent and light-guiding or opaque and reflective. For example, after light enters the first carrier layer and is guided into the second carrier layer, the second carrier layer may be set to be transparent to guide the light to the light-receiving device below, such as the battery cell, or it may be set to be reflective to reflect the light back to the battery cell located above.

[0043] It should be noted that the aforementioned functional membrane can also be located at critical locations within the component (between or at the edges of PV sheets, between display layers, or at the edge of the encapsulation); since this functional membrane is typically distributed throughout the entire component or a large area, this allows interactive functions based on these cavities (such as sensing and repair) to form a distributed network, enabling detailed monitoring or uniform intervention over a large area, and the functions can be directly integrated into the existing structure; micron-level cavities have characteristics such as high specific surface area, potential capillary effects, and restriction of reactant diffusion paths, which are difficult to achieve in macroscopic structures, allowing the structure provided in this application to be located on the functional membrane rather than in other easily processed, larger locations.

[0044] As an example, this embodiment provides a functional film for photovoltaic modules with localized moisture indication function in the PV field. It is applied to photovoltaic modules and its main function is optical assistance (e.g., improving the light utilization rate inside the module), with the additional function of indicating localized moisture intrusion.

[0045] In order to achieve moisture indication without significantly affecting the overall optical performance, moisture indication material is provided only in a portion of the first cavity at a specific pre-selected location of the functional film (e.g., along the edge region of the photovoltaic module or near a known weak point in the encapsulation), or in a local area of ​​the inner wall of the opening channel of the portion of the first cavity.

[0046] Moisture indicator materials are, for example, color-changing materials sensitive to ambient humidity, such as anhydrous cobalt chloride thin coatings or other humidity-sensitive dyes embedded in a porous transparent matrix. The moisture indicator material is applied in a small, thin layer, for example, by spraying, dotting, or impregnation followed by removal of excess material, onto a non-primary optical surface of the inner wall of the selected cavity, thus minimizing its volume or coverage area within the cavity.

[0047] When a trace amount of moisture seeps into a specific area of ​​the photovoltaic module's encapsulation, the moisture molecules can enter a selected first cavity containing a moisture indicator material through the opening channel of the first cavity. Upon contact with the moisture, the moisture indicator material undergoes a visually observable color change. Because the indicator is applied in minute quantities only in localized or partial cavities, and the indicator itself can be selected from materials with minimal impact on the operating spectrum or applied to non-optically critical surfaces, the main light-guiding path and overall optical efficiency of the functional film are essentially maintained. By periodically visually inspecting these predetermined cavities or conducting routine inspections using simple optical instruments, it is possible to determine whether there is a risk of early moisture intrusion in the corresponding parts of the module, thereby achieving low-cost condition monitoring with minimal impact on optical performance.

[0048] As a feasible approach, when a functional film is located within a photovoltaic module, it can effectively utilize scattered and low-angle incident light that might otherwise be wasted. In practical photovoltaic applications, due to environmental factors (such as early morning / evening hours, cloudy days, etc.), light does not always strike the solar cells perpendicularly. The functional film's special cavity structure can capture this non-perpendicularly incident light. The light is guided into the cavity through the opening channel of the first cavity, undergoing multiple reflections and refractions on the inner wall of the cavity, changing the direction of light propagation, and ultimately efficiently guiding the light to the light-receiving surface of the solar cells. This not only increases the amount of light absorbed by the solar cells but also reduces optical losses caused by gaps between solar cells, thereby improving the overall power generation efficiency of the photovoltaic module. Furthermore, the functional film also acts as a buffer, reducing relative displacement between solar cells caused by thermal expansion and contraction, lowering the risk of microcracks in the solar cells, and improving the reliability and lifespan of the photovoltaic module.

[0049] As another feasible approach, in display devices, a liquid crystal layer or organic light-emitting layer is typically sandwiched between two glass substrates. A functional film located between the two glass substrates can optimize the propagation path of light within these functional layers. The arrangement of the first and second carrier layers, along with the optical function of the first cavity, enables precise control of the light emitted from the backlight. For example, by collimating and guiding the light, it allows the light to pass through the liquid crystal layer or organic light-emitting layer more uniformly, reducing light scattering and loss, thereby improving the brightness uniformity and contrast of the displayed image. Simultaneously, the functional film can effectively suppress crosstalk between adjacent pixels. Due to the constraint effect of the cavity structure on the light, the light emitted from each pixel can reach its corresponding display area more accurately, preventing light leakage to adjacent pixels and improving the clarity and color reproduction of the displayed image. Furthermore, the functional film can provide a certain degree of mechanical support for the two glass substrates, enhancing the overall structural stability of the display device and preventing deformation of the glass substrates due to external forces from affecting the display effect.

[0050] The bezel area of ​​display devices may suffer from uneven light reflection and refraction, resulting in bright or dark edges that affect display quality. Placing a functional film between the glass substrate and the bezel can improve this situation. Its unique cavity opening channel and optical structure can redistribute and correct light near the bezel. By adjusting the angle of the first cavity opening channel and the optical parameters of the cavity, light can propagate more smoothly in the transition area between the bezel and the glass substrate, reducing visual defects caused by light reflection and scattering, and improving the overall aesthetics of the display image. Furthermore, the functional film can form a barrier between the glass substrate and the bezel, preventing external dust, moisture, and other contaminants from entering the display device, protecting internal optical and electronic components from contamination and corrosion, and extending the lifespan of the display device.

[0051] As another example, the functional film for display devices in this application has the function of passive adsorption of internal volatiles: Volatile organic compounds (VOCs) are generated inside the display. This is a common phenomenon in electronic device manufacturing, but it is particularly noteworthy in display devices where optical performance and material stability are extremely important. Sources include adhesives, glues, plastic parts, etc. Evaporation can lead to surface optical contamination (fogging) and condensation into oil mist at lower temperatures. In order to achieve VOCs adsorption without significantly interfering with the internal optical path of the display device, a thin, porous VOCs adsorbent is coated or deposited only on the inner wall surface of a portion of the first cavity in the functional film adjacent to potential VOCs release sources (e.g., near the adhesive layer, plastic frame, or edge of a flexible circuit board).

[0052] VOCs adsorbents are, for example, transparent or semi-transparent materials with microporous or mesoporous structures, such as modified silica aerogel films, transparent metal-organic framework (MOF) nanocoatings, or transparent polymer coatings loaded with activated carbon particles (dispersed in a very low concentration in a transparent binder to form a thin film). The thickness of the adsorbent layer is preferably controlled in the submicron to several micrometer range, ensuring low light absorption and scattering within the operating wavelength range of the display device.

[0053] Because the adsorbent is applied only locally and in a thin layer, and the material itself has a certain degree of optical compatibility, the impact on the overall brightness, contrast, color gamut, and other core optical indicators of the display device can be controlled within acceptable limits. This design, through passive adsorption, reduces the risk of VOCs condensing or causing chemical pollution on sensitive optical components inside the display device (such as polarizers, quantum dot films, and the display panel surface), thus helping to maintain the long-term stability of display quality.

[0054] The openness of this functional membrane is reflected in (1) the existence of an open channel that connects with the outside world; and (2) the design of the double-layer structure, which forms an interconnected three-dimensional network. The three-dimensional open network has better design space to realize multi-dimensional optical control, enhanced material transport and synergistic optimization of mechanical properties.

[0055] As another example, this application also provides the application of a three-dimensional functional film with tunable mechanical properties in a flexible display device: a first carrier layer includes a plurality of first cavities extending along a predetermined first principal axis direction (the bending axis of the flexible device). The orientation and geometry of the first cavities (e.g., a high aspect ratio and a specific packing density) are configured to primarily reduce the bending stiffness of the functional film along the first principal axis direction, thereby enhancing its flexibility in that direction. The open nature of the first cavities helps to prevent the accumulation of internal gas pressure during bending deformation.

[0056] The second carrier layer is bonded to the first carrier layer and includes a plurality of second cavities extending along a predetermined second principal axis direction. The second principal axis direction is, for example, perpendicular to the first principal axis direction or at a non-zero predetermined angle. The orientation and geometry of the second cavities (e.g., different from the size, density, or wall thickness of the first cavities) are configured to primarily provide the structural stability or deformation resistance required by the functional membrane in the second principal axis direction.

[0057] Understandably, traditional closed cavities require high-precision lamination processes to ensure a completely sealed cavity between the upper and lower carrier layers. This places extremely high demands on material flatness, interlayer alignment accuracy, pressure, and temperature control, resulting in a complex manufacturing process and limited yield. The non-closed cavity provided in this application, on the one hand, allows for the existence of certain interlayer microchannels in terms of manufacturing complexity, reducing the requirement for complete interlayer sealing. On the other hand, in terms of product lifespan, the open channels allow for gas escape and stress relief, reducing the risk of board bursting caused by uneven lamination pressure, differences in material thermal expansion, and heat accumulation during long-term use.

[0058] This application provides a functional membrane comprising at least two carrier layers, including a first carrier layer and at least one second carrier layer. The first carrier layer is transparent at least in its optical functional region and has at least one first surface structure on its surface. The second carrier layer is fixedly bonded to the first carrier layer, forming at least one optically functional first cavity between the first surface structure of the first carrier layer and the second carrier layer. The first cavity communicates with the external environment of the functional membrane through at least one opening channel, which is defined by the structure of the first carrier layer, the second carrier layer, or a combination thereof. The opening channel has at least one opening, and the normal direction of the opening plane is either horizontal or at a first predetermined angle to the horizontal plane. Compared with the prior art, the functional membrane of this application achieves internal pressure self-balancing through its open cavity structure, avoiding the accumulation of internal thermal stress caused by temperature changes. This reduces the risk of delamination of the laminated structure or component failure, enhances the long-term weather resistance of the product, and significantly improves structural reliability. Furthermore, it combines openness with anti-contamination capabilities: thanks to its structural design where the opening normal direction does not face upwards, and optionally combined with a self-cleaning layer or microgrid, it achieves effective defense against external contaminants while possessing the advantages of open channels (such as pressure equalization and moisture dissipation); and its multi-layered, multi-directional cavity network design breaks the limitations of two-dimensional planar structures, providing a new design platform for achieving multi-dimensional fine control of the light field, or for customizing specific directional flexibility and stiffness mechanical properties for flexible and foldable devices; it can expand functional integration and application modes, conveniently integrating reflective, thermally conductive and other functional materials, transforming functional films from single optical transmission / guiding elements into platform devices that can achieve composite functions such as high-efficiency reflection and thermal management, and since it does not require absolute hermetic sealing of the cavity, it is expected to simplify the stringent requirements of manufacturing processes such as lamination, which will help improve production yield and reduce costs.

[0059] In one embodiment, the functional membrane includes at least a first set of cavities and a second set of cavities, the first set of cavities extending along a first direction and the second set of cavities extending along a second direction, wherein both the first and second directions are perpendicular to the thickness direction of the functional membrane, and the first and second directions form a second preset angle.

[0060] Specifically, the first carrier layer has a first set of cavities in a first direction, and the second carrier layer has a second set of cavities in a second direction. Both the first and second directions are perpendicular to the lamination direction, but they are not parallel. For example, the first and second directions are staggered at a second preset angle of 45°, or they can be staggered at a second preset angle of 30°. This second preset angle can be customized according to the angle of sunlight irradiation on the functional film at different times, as long as it can improve the light capture efficiency.

[0061] In one implementation, please refer to [link / reference]. Figure 2 As shown, the first carrier layer 10 has a first cavity 11 and a first cavity opening channel 13 that extend in a first direction, and the second carrier layer 20 has a second cavity 21 and a second cavity opening channel 23 that extend in a second direction. The intersection angle between the first and second directions is 90°. For another implementation, please refer to... Figure 3 As shown, Figure 3 This is a top view schematic diagram of the functional membrane provided in an embodiment of this application. By alternating the first cavities of the first carrier layer and the second cavities of the second carrier layer, the light-gathering efficiency can be improved. Under other limited conditions, the higher the density of the second cavities in the second carrier layer, the better the light-gathering effect. For another implementation, please refer to... Figure 4 As shown, the first carrier layer 10 in this functional membrane has a first cavity 11 and a first cavity opening channel 13 that extend in a first direction, and the second carrier layer 20 has a second cavity 21 that extends in a second direction. The intersection angle between the first direction and the second direction is 45°. The left and right portions of the second cavity 21 of the second carrier layer 20 are mirror images of each other, and both are at an angle of 45° to the first direction. Figure 4 The right side of the second carrier layer is not shown. For another implementation, please refer to [link / reference]. Figure 5 As shown, the first carrier layer 10 in this functional membrane does not have a cavity opening channel, while the second carrier layer 20 has a second cavity 21 and a second cavity opening channel 23. Please refer to... Figure 6 and Figure 7 Show, Figure 6 This is a schematic diagram of the structure of the first carrier layer 10 provided in an embodiment of this application. Figure 7 This is a schematic diagram of the structure of the second carrier layer 20 provided in the embodiment of this application. The second carrier layer 20 has a channel cavity and a non-channel cavity structure. The channel cavity has at least one second cavity 21 and a second cavity opening channel 23. The closure of the cavity is not shown in the figure. The channel cavity is set at an inclined horizontal plane and the corresponding channel opening is relatively large. A self-cleaning material can be provided at the channel opening.

[0062] For example, taking the first set of cavities extending in the first direction as triangular cavities and the first set of cavities extending in the second direction as triangular cavities, the first carrier layer has a triangular cavity extending in the first direction and the second carrier layer has a triangular cavity extending in the second direction. Both the first direction and the second direction are perpendicular to the lamination direction and not parallel to it.

[0063] In this embodiment, by setting the first and second cavities of the upper and lower layers as triangular cavities, an acute-angle reflective surface is formed, which has the ability to reflect incident light in a directional manner. This allows the light to be reflected at a fixed angle, which facilitates precise control of the pipeline and improves the light reflection efficiency. Furthermore, the triangular cavity that runs through the first direction can guide the light in the horizontal direction (such as east-west), and the cavity that runs through the second direction can guide the light in the vertical direction (such as north-south), forming a cross-shaped three-dimensional light path network. The through-type structure avoids the light interception at the end of the cavity, allowing the light to enter from one end and pass through from the other end. Combined with a high-reflection coating (such as an aluminum film), the number of light reflections is increased, significantly improving the light utilization rate, especially improving the capture efficiency of low-angle light during dawn and dusk.

[0064] The surface of the at least one second carrier layer 20 is provided with at least one second surface structure to form at least one second cavity between the second carrier layer and the first carrier layer; and the first set of cavities is formed by the first surface structure, and the second set of cavities is formed by at least one second surface structure.

[0065] It should be noted that the aforementioned second surface structure is located on the surface of the second carrier layer, and forms at least one second cavity between it and the first carrier layer.

[0066] In one embodiment, at least one cavity in the first group of cavities is interconnected with at least one cavity in the second group of cavities to form a three-dimensional open cavity network.

[0067] The interconnection of at least one first surface structure with at least one second surface structure to form an interconnected cavity can refer to one first surface structure interconnecting with one second surface structure to form an interconnected cavity, two first surface structures interconnecting with one second surface structure to form an interconnected cavity, or multiple first surface structures interconnecting with multiple second surface structures to form an interconnected cavity.

[0068] The aforementioned functional membrane may have at least one cavity opening channel connected to the outside. For example, the first carrier layer 10 provides a channel to the outside through the first cavity opening channel 13; or, the first carrier layer does not provide the first cavity opening channel 13, and the second carrier layer 20 provides a cavity opening channel through interconnection; or, both the first carrier layer 10 and the second carrier layer 20 provide cavity opening channels, that is, the first carrier layer 10 provides the first cavity opening channel 13 and the second carrier layer 20 provides the second cavity opening channel 23.

[0069] In this embodiment, the functional membrane is connected to the outside through at least one cavity opening channel. This reduces the exposed area of ​​the cavity, preventing large-scale entry of contaminants into the cavity, reducing air refraction loss inside the cavity, improving light transmission efficiency, and the inert gas filling can inhibit water vapor erosion or oxidation reactions inside the cavity, extending the module's lifespan. Simultaneously, when photovoltaic modules or display devices operate in high and low temperature environments, the medium inside the cavity will generate stress due to thermal expansion and contraction. Connecting the cavity opening channel to the outside can release some of this stress, preventing the carrier layer from cracking due to stress concentration (traditional enamel-coated glass is prone to breakage due to thermal stress). Furthermore, compared to traditional closed-loop laminated structures, in this application, when the medium inside the cavity ages or becomes contaminated, it can be replaced or cleaned through the cavity opening channel, reducing maintenance costs. By providing at least one cavity opening channel, light can also be guided for multi-angle reflection / refraction, improving light absorption or uniformity.

[0070] In one embodiment, each first surface structure is arranged on the surface of the first carrier layer according to a first distribution rule, and / or each second surface structure is arranged on the surface of the second carrier layer according to a second distribution rule; wherein the first distribution rule and the second distribution rule are the same or different, and both the first distribution rule and the second distribution rule include at least one of the following: uniform distribution, gradient distribution, periodic non-uniform distribution, and function-oriented distribution.

[0071] It should be noted that the first and second distribution rules mentioned above can be customized according to the actual angle at which light enters the functional membrane, in order to increase the amount of light entering the functional membrane.

[0072] The aforementioned uniform distribution refers to cavities arranged at the same intervals and sizes across the entire carrier layer. This method is typically used in applications requiring consistent material properties or uniform fluid flow. Gradient distribution refers to cavities whose density, size, or other characteristics gradually change along one direction. For example, in some applications, it may be desirable to gradually increase the number or size of cavities from one end to the other to achieve specific functions, such as controlling mass transfer rates or adjusting mechanical strength. Periodic non-uniform distribution can be understood as follows: although the cavities appear to repeat according to a certain period, the layout and size of the cavities may vary within each period. This allows designers to customize the properties of local areas according to specific needs. Function-oriented distribution refers to the specific distribution of cavities determined by the product's functional requirements. For example, in solar cells, cavity distribution is specifically designed to maximize light absorption efficiency; or in electronic devices, thermal conduction channel distribution is designed to optimize heat dissipation.

[0073] The different distribution methods mentioned above need to be rationally selected and designed based on the actual application requirements, the feasibility of the manufacturing process, and the expected technical effects, so as to effectively improve the performance and reliability of the functional membrane.

[0074] In this embodiment, the aforementioned first cavities may be of the same or different sizes, for example, they may all be triangular cavities and uniformly distributed on the surface of the first carrier layer. Similarly, the aforementioned second cavities may be of the same or different sizes, for example, they may all be triangular cavities and uniformly distributed on the surface of the first carrier layer.

[0075] For example, based on the established distribution rules, since the cavity opening channels are susceptible to contamination, especially EVA adhesive leakage, the aforementioned functional membrane can have only one cavity opening channel connected to the outside. Optionally, the aforementioned first cavities can be uniformly distributed on the surface of the first carrier layer, and the second cavities can be non-uniformly distributed on the surface of the second carrier layer; the first cavities can also be non-uniformly distributed on the surface of the first carrier layer, and the second cavities can be uniformly distributed on the surface of the second carrier layer; or the first cavities can be uniformly distributed on the surface of the first carrier layer, and the second cavities can also be uniformly distributed on the surface of the second carrier layer. Regardless of the corresponding distribution of the first and second cavities on their respective carrier layers, the functional membrane has only one cavity opening channel connected to the outside. This can be either a first cavity opening channel only in the first cavity or a second cavity opening channel only in the second cavity.

[0076] The aforementioned second cavity includes a channel cavity and a non-channel cavity. The channel cavity and the non-channel cavity are evenly distributed on the surface of the second carrier layer. The channel cavity has at least one second cavity opening channel.

[0077] It is understood that the aforementioned channel cavity has a second cavity opening channel that directly connects to the outside, and the channel direction is at a first preset angle to the horizontal plane (such as being nearly vertical or inclined). The cavity size of the channel cavity is usually larger than that of the non-channel cavity, for example, the depth of the channel cavity is 30% greater than that of the non-channel cavity, and the opening width of the channel cavity is 50% larger than that of the non-channel cavity, in order to improve the efficiency of medium flow or the light guiding capability.

[0078] The aforementioned non-channel cavities have no external openings. They are connected to the channel cavities or the first cavity through interconnected cavity structures to form a closed optical path. Their cavity size is small and they are densely distributed, which can improve light scattering or reflection efficiency through dense arrangement.

[0079] The aforementioned channel cavities and non-channel cavities can be arranged in a periodic matrix (such as a checkerboard pattern) to ensure that the incident / reflected light is evenly distributed on the surface of the second carrier layer.

[0080] In one embodiment, at least one opening or opening channel is provided with a self-cleaning layer or microgrid.

[0081] Specifically, the channel direction of the first cavity opening channel forms a preset angle with the horizontal plane and a self-cleaning layer or microgrid is provided inside the channel, and / or, the channel direction of the second cavity opening channel forms a preset angle with the horizontal plane and a self-cleaning layer or microgrid is provided inside the channel.

[0082] For example, the channel cavities on the surface of the second carrier layer can be equilateral triangles with a side length of 200 μm and a cavity depth of 150 μm. The angle between the corresponding second cavity opening channel and the horizontal plane can be 80° (close to vertical), and they are evenly distributed on the surface of the second carrier layer at a spacing of 500 μm. The non-channel cavities can be isosceles triangles with a base of 100 μm and a cavity depth of 00 μm, densely arranged between the channel cavities to form a periodic array of "large triangles + small triangles". Each channel cavity is connected to the outside through a top opening and connected to the four adjacent non-channel cavities through a hypotenuse at the bottom, thereby forming a "one-in-four-out" optical path network.

[0083] In this embodiment, channel cavities are set up as the main channels for light incident / exit. By optimizing the opening channel angle (e.g., 45° tilt), light at a specific angle is guided into the cavity network, or reflected light is converged to the solar cell / display panel. By designing the channel cavities and non-channel cavities on the surface of the second carrier layer according to a certain distribution rule, the interlayer stress can be balanced, preventing the risk of cracking caused by the dense local cavity.

[0084] The first cavity opening channel has a channel direction that forms a preset angle with the horizontal plane and is provided with a self-cleaning layer or microgrid inside the channel, and / or the second cavity opening channel has a channel direction that forms a preset angle with the horizontal plane and is provided with a self-cleaning layer or microgrid inside the channel.

[0085] It should be noted that the aforementioned self-cleaning layer can be any material used for surface self-cleaning of the functional membrane, including a nano-TiO2 coating or a fluoropolymer coating. Under ultraviolet light irradiation, TiO2 generates hydroxyl radicals, decomposing organic contaminants within the channels (such as EVA adhesive leakage and fingerprint stains). It also exhibits superhydrophilicity, with a contact angle of <5° with the coating surface, allowing water to form a uniform film that carries away dust, achieving a "self-cleaning" effect. The fluoropolymer coating has a low-energy surface, preventing the adhesion of adhesives or stains, making it suitable for gaps in photovoltaic module frames. The preset angle between the channel direction of the second cavity opening and the horizontal plane can be 60°-90°, and can be customized according to actual needs.

[0086] The aforementioned microgrid serves for physical filtration and structural reinforcement, blocking particles larger than a preset diameter from entering the cavity while allowing gases (such as air and inert gases) and liquids (such as optical adhesives) to pass through, achieving "selective permeability." Optionally, the microgrid can be rigid or flexible. Rigid microgrids can be manufactured using a metal electroplating process to provide mechanical support and prevent the channels from deforming due to external forces. Flexible microgrids can be made of PDMS (polydimethylsiloxane) material, which can bend with the carrier layer, making them suitable for curved display devices.

[0087] In this embodiment, a microgrid is used to block large particulate contaminants, while a self-cleaning layer degrades small molecular contaminants (such as oil mist). The combination of these two methods keeps the cavity opening channel clean for a long time. Especially in the cavity opening channel of the functional film located between the solar cell and the frame, the microgrid can intercept particles overflowing from the frame sealant, and the self-cleaning layer decomposes the organic matter volatilized from the sealant, preventing contamination of the cell surface. Furthermore, by positioning the cavity opening channel at a predetermined angle to the horizontal plane, more light can be captured, improving optical efficiency, anti-contamination capability, and mechanical reliability.

[0088] In one embodiment, the second carrier layer includes at least one reflective component having at least one reflective surface facing the first carrier layer.

[0089] It should be noted that the second carrier layer may be opaque, transparent and light-guiding, or reflective. Specifically, a reflective material may be disposed inside the opening channel of the second cavity, with the reflectivity of the reflective material exceeding a reflectivity threshold, and the reflectivity of the thermally conductive material exceeding a thermal conductivity threshold.

[0090] In one embodiment, the second carrier layer provides a reflective surface with reflective functionality (or it can be a light guide + reflector). Specifically, this reflective surface can be achieved, but is not limited to, by depositing a thin metal film (such as silver or aluminum) on the surface of the second carrier layer or the second cavity; or by depositing multiple dielectric films to form a high-reflectivity mirror; or by the second carrier layer itself being made of an opaque material with high reflectivity. This reflective surface is used to reflect light emitted from or propagating to the first cavity back in a predetermined direction, for example, in photovoltaic applications, reflecting it back to the solar cell above for secondary absorption.

[0091] In one embodiment, the first carrier layer and / or the second carrier layer contain a thermally conductive material to improve the thermal conductivity of the functional membrane.

[0092] The second carrier layer is provided with a thermally conductive material, and / or the first carrier layer is provided with a thermally conductive material, wherein the thermal conductivity of the thermally conductive material is greater than the thermal conductivity threshold.

[0093] It should be noted that the aforementioned second carrier layer can be disposed below the first carrier layer, and the second carrier layer can have a microstructure with a cavity coated with a metallic reflective film. The aforementioned reflectivity threshold and thermal conductivity threshold can be customized according to actual needs, for example, a reflectivity threshold of 70% and a thermal conductivity threshold of 0.4 W / m*K. The inner side of the second cavity opening channel provided by the second carrier layer grid can be provided with a reflective material containing more than 70% reflective material, and the second carrier layer is provided with a thermally conductive material with a thermal conductivity higher than 0.4 W / m*K.

[0094] For example, a TiO2 nanorod array can be embedded in the second carrier layer substrate. This nanorod array may include nanorods with a diameter of 20 nm and a length of 100 nm, oriented along a second direction to scatter short-wavelength light (300-700 nm), increasing haze to 35% and enhancing light absorption on the front surface of the solar cell. The nanorods form a thermal conductivity path, increasing the thermal conductivity along the second direction from only 0.22 W / m·K compared to traditional PET substrates to 0.45 W / m·K, thus rapidly dissipating waste heat generated by long-wavelength light (>700 nm).

[0095] In one possible implementation, the functional film may consist only of a reflective material with a reflectivity greater than a reflectivity threshold disposed on the inner side of the second cavity opening channel, and a thermally conductive material with a thermal conductivity greater than or equal to a thermal conductivity threshold disposed on the second carrier layer. In another possible implementation, the functional film may consist only of a thermally conductive material with a thermal conductivity greater than a thermal conductivity threshold disposed on the first carrier layer. In yet another possible implementation, the functional film may consist not only of a reflective material with a reflectivity greater than a reflectivity threshold disposed on the inner side of the second cavity opening channel, and a thermally conductive material with a thermal conductivity greater than or equal to a thermal conductivity threshold disposed on the second carrier layer, but also of a thermally conductive material with a thermal conductivity greater than or equal to a thermal conductivity threshold disposed on the first carrier layer.

[0096] The aforementioned reflective materials can include aluminum-coated films or silicon dioxide (SiO2) microsphere coatings. Aluminum-coated films can achieve a reflectivity of over 90%, providing highly efficient reflection of the entire visible light spectrum (400-760nm), making them particularly suitable for broad-spectrum light capture in photovoltaic modules. Silicon dioxide (SiO2) microsphere coatings convert direct light into scattered light through diffuse reflection, increasing haze to 35%, making them suitable for backlight uniformity in display devices (such as Mini LED modules).

[0097] The aforementioned thermally conductive materials can include filler-type composite materials and nanorod arrays for directional thermal conduction. Filler-type composite materials consist of alumina (Al2O3), boron nitride (BN), graphene, and other fillers dispersed in the second carrier layer substrate (such as PET or COC). The thermal conductivity is increased from 0.22 W / m·K for traditional PET to 0.45-0.8 W / m·K (e.g., 0.6 W / m·K with a BN content of 20%). The nanorod array method involves embedding TiO2 nanorods to form a one-dimensional thermally conductive channel, increasing the thermal conductivity along the cavity direction (second direction) to 0.45 W / m·K, which is 100% higher than traditional unfilled structures.

[0098] Optionally, the aforementioned reflective coating (such as aluminum plating) and thermally conductive filler can be simultaneously integrated into the second carrier layer via a roll-to-roll (R2R) process to avoid alignment errors in traditional step-by-step processing and thus improve yield.

[0099] In this embodiment, the use of high reflectivity and high thermal conductivity materials in the second carrier layer breaks through the single performance limitations of traditional functional films that prioritize either optics or heat dissipation. By using multiple reflections, the light utilization rate is improved, adapting to incident light at different angles. Furthermore, it can quickly dissipate waste heat, alleviating hot spot effects and material aging. At the same time, it reduces the risk of panel explosion, broadens the range of applicable environments, and lowers manufacturing costs, providing key technical support for improving the efficiency and cost reduction of photovoltaic modules and the high reliability of display devices.

[0100] On the other hand, this application provides a photovoltaic module, including the functional film and solar cells provided in the above embodiments, wherein the functional film is located on the surface of the solar cells, between two solar cells, and between the solar cells and the module frame.

[0101] Optionally, the aforementioned functional film can be disposed in the gaps between solar cells, in the gaps between the solar cells and the module frame, or directly above or below the solar cells. Specifically, the functional film can fill the physical gaps between adjacent solar cells. Its main function is to capture and effectively utilize light incident on these non-efficient power generation areas, for example, by redirecting light to the surface of adjacent solar cells through its internal reflection or scattering structures, thereby improving the overall photoelectric conversion efficiency of the photovoltaic module.

[0102] Specifically, the functional film can be filled between the outermost solar cells and the metal or non-metal frame of the photovoltaic module. Besides managing edge light loss, its function is to provide mechanical cushioning and absorb stress caused by thermal expansion and contraction or external impacts. Furthermore, since the module edges are weak points susceptible to intrusion from environmental factors such as moisture, this location is also an ideal area for integrating monitoring sensors (as described in the above embodiments) to assess the long-term reliability of the module. The functional film can be located on the top / bottom of the solar cells; since photovoltaic panels are now bi-sided, it can guide light to both the front and back sides.

[0103] The functional film provided in this embodiment can be applied inside a photovoltaic module, filling the gaps between solar cells or the surface of solar cells, improving the overall luminous efficiency of the photovoltaic module. It can also be positioned between the solar cells and the frame to reduce light loss caused by frame shading, while simultaneously providing auxiliary heat dissipation, further improving light utilization. Furthermore, the first cavity communicates with the external environment of the functional film through at least one opening channel. The opening channel has at least one opening, and the normal direction of the opening plane is either horizontal or at a first preset angle to the horizontal plane. This inclined design effectively prevents external contaminants from entering, controls fluid flow direction, and optimizes the incident angle of light.

[0104] On the other hand, this application provides a display device including the functional film and glass substrate provided in the above embodiments, wherein the functional film is located between the two glass substrates or between the glass substrate and the device frame.

[0105] Optionally, the aforementioned functional film can be disposed in the peripheral area of ​​the display panel (e.g., between the bezel and the panel), or in the internal optical stacking layer of the display module, or in the bending area of ​​a flexible or foldable display device. Specifically, it can be disposed between the edge of the display panel and the device frame or housing, serving as a highly reliable buffer pad to manage edge light leakage, or as a substrate for carrying water and oxygen sensors to monitor the encapsulation integrity of sensitive panels such as OLED / QLED. It can also be integrated into the optical path of the display module as a functional optical film. For example, in the backlight module of an LCD, it can be placed between the light guide plate and the prism film (brightness enhancement film) to provide optical control functions such as light uniformity, wide viewing angle, or collimation, and its open cavity structure avoids optical defects such as Newton's rings during interlayer bonding.

[0106] Placing the film in the bending area of ​​a flexible or foldable display device is an application targeting emerging flexible devices. By placing the functional film provided in this application (especially one with customized mechanical properties, as described in the embodiments) at the bending point (hinge area) of the screen stack, it can serve as a core stress-relieving and support layer, greatly improving the mechanical durability of the screen during repeated folding and helping to reduce crease formation.

[0107] The functional film provided in this application embodiment, with its open three-dimensional cavity network, can fill the gaps between the cells and the frame area of ​​the photovoltaic module, while efficiently capturing and utilizing the gap light energy, giving the module an inherent pressure self-balancing and long-term reliability monitoring capability; and the optical functional film, with its unique open cavity structure, can be strategically placed in the peripheral area of ​​the display device to achieve encapsulation monitoring and light leakage management, or placed in the internal interlayer and bending areas to provide precise optical control and key mechanical support.

[0108] On the other hand, embodiments of this application provide a method for manufacturing a functional membrane, applicable to the functional membrane provided in the above embodiments. Please refer to... Figure 8 As shown, the manufacturing method of the above-mentioned functional membrane includes:

[0109] S101. Obtain a first carrier layer; the first carrier layer is transparent at least in its optical functional area, and at least one first surface structure is provided on its surface.

[0110] S102, Obtain the second carrier layer.

[0111] S103. The first carrier layer and the second carrier layer are fixedly bonded to form a functional film; at least one first cavity with optical function is formed between the first surface structure of the first carrier layer and the second carrier layer; wherein the first cavity is connected to the external environment of the functional film through at least one opening channel, the opening channel being defined by the structure of the first carrier layer, the second carrier layer or a combination thereof; and the opening channel having at least one opening, the normal direction of the opening plane being set at a horizontal plane or at a first preset angle to the horizontal plane.

[0112] Specifically, in obtaining the first carrier layer, a suitable light-transmitting material can be selected based on the application scenario requirements. For photovoltaic modules, polyethylene terephthalate (PET) can be used, as it has high light transmittance, good mechanical strength, and chemical stability. For display devices, cyclic olefin copolymers (COC) can be considered due to their low hygroscopicity and low birefringence, ensuring display clarity. After determining the light-transmitting material, precision micro-nano fabrication technology is used to construct multiple first surface structures on the surface of the first carrier layer. Taking photolithography as an example, photoresist is first coated onto the surface of the first carrier layer. The designed cavity and opening patterns are then exposed using a photomask. After development and etching processes, the unexposed photoresist and carrier layer material are removed, thus forming a first surface structure with a specific shape and size. This first surface structure can include triangular cavities, rectangular cavities, trapezoidal cavities, hexagonal cavities, curved cavities, etc.

[0113] It should be noted that, in order to ensure efficient light transmission within the functional membrane, the size and shape of the first cavity opening channel must be precisely controlled. For example, the channel diameter can be controlled at the micrometer level to match the light propagation characteristics. Simultaneously, the first carrier layer undergoes quality inspection. An optical microscope is used to check whether the edges of the cavity and opening are smooth and whether the dimensions meet design requirements. Defective products are screened and reworked until they meet the design requirements.

[0114] After obtaining the first carrier layer, a second carrier layer is obtained. The material selection for this second carrier layer can be the same as or complementary to that of the first carrier layer. During the production process, the flatness and thickness uniformity of the second carrier layer are strictly controlled. High-precision casting or calendering processes are used to ensure that the thickness tolerance is controlled within a very small range, such as ±5μm. Before the raw materials are stored, their optical performance indicators, such as light transmittance and haze, are tested to ensure that the light transmittance of the second carrier layer is not less than 90% and the haze is less than 1%, thus meeting the optical performance requirements of the functional film.

[0115] Optionally, at least one optically functional first cavity is formed between the first surface structure of the first carrier layer and the second carrier layer. The first carrier layer and the second carrier layer can be obtained through processes including molding, rolling, photolithography, laser processing, or imprinting. The first cavity communicates with the external environment of the functional film through at least one opening channel, which is defined by the structure of the first carrier layer, the second carrier layer, or a combination thereof; and the opening channel has at least one opening, the normal direction of the opening plane being set at a horizontal plane or at a first preset angle to the horizontal plane.

[0116] When the first and second carrier layers are obtained, they are connected. The connection method can be chosen based on actual needs, such as physical contact, adhesion, or lamination. If adhesion is used, an optically transparent adhesive with high bonding strength, such as optical-grade silicone, can be selected. The adhesive is evenly applied to the surface of the first cavity of the first carrier layer, and then the second carrier layer is precisely aligned and bonded. Heating and curing are then used to tightly connect the two layers, forming a functional film. In the lamination process, temperature, pressure, and time parameters must be precisely controlled. For example, the temperature should be controlled at 120℃-150℃, the pressure at 0.5-1.0 MPa, and the time at 5-10 minutes to ensure that the two layers are fully fused without defects such as bubbles or deformation.

[0117] To ensure that the normal direction of the opening plane is set to the horizontal plane or at a first preset angle to the horizontal plane, high-precision alignment equipment, such as an automatic alignment system based on machine vision, can be used to achieve micron-level precise alignment by identifying marker points on the carrier layer, controlling the deviation between the first and second directions within ±1°. Simultaneously, molds or fixtures are used to fix the opening direction of the cavity opening channel, ensuring that its angle with the horizontal plane meets the first preset angle requirement, with the angle error controlled within ±2°. After connection, the functional film undergoes overall performance testing, including optical performance testing (such as transmittance, reflectivity, and light distribution uniformity) and mechanical performance testing (such as tensile strength and peel strength), to ensure that the functional film meets the application requirements of photovoltaic modules or display devices.

[0118] It is understood that the aforementioned functional membrane may include single-layer anisotropic and multi-layer anisotropic structures. Specifically, single-layer anisotropic means that only the first carrier layer has a group of cavities with multiple directions; multi-layer anisotropic means that the first layer has a group of cavities with multiple directions, and the second layer has a group of cavities with multiple directions.

[0119] This embodiment, by setting up a multi-layered anisotropic structure, allows for the independent and decoupled design of the cavity structure and materials of each layer. This enables the simultaneous optimization of multiple properties that would otherwise be mutually constrained in a single layer (such as optical transmittance in one direction and mechanical flexibility in another), thereby achieving an optimal performance combination that a single-layer structure cannot achieve. Furthermore, it generates a three-dimensional mechanical enhancement effect: the multi-layered structure forms a three-dimensional support system similar to an I-beam, improving resistance to Z-axis (thickness direction) pressure and buckling stability. If the layers are interconnected, the resulting three-dimensional network can more effectively disperse stress, thereby significantly improving fatigue and tear resistance. It also enables the superposition of tandem optical functions: light can pass sequentially through cavity layers located at different optical depths, allowing for tandem optical functions, such as designing one layer as a collimation layer and another as a diffusion layer. Although this increases the interlayer alignment process, it significantly reduces the difficulty and cost of core master plate fabrication, making mass production more feasible in many cases.

[0120] In this embodiment, a first carrier layer and a second carrier layer are obtained, and a first cavity and a corresponding opening channel are precisely constructed. Then, the first carrier layer and the second carrier layer are connected by physical connection or bonding to create a functional membrane, thereby reducing manufacturing costs. Furthermore, by setting an inclined opening channel, the light path can be effectively guided, allowing the light to undergo multiple reflections or refractions within the structure, reducing surface reflection and scattering losses, and thus improving light utilization efficiency. Compared with existing laminated structures, the functional membrane structure of this application optimizes the cavity design, reduces stress loss caused by temperature changes or external pressure, enhances the stability of the overall structure, and reduces the risk of plate bursting.

[0121] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0122] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A functional membrane, characterized in that, For use inside photovoltaic modules or display devices, the functional film includes at least two carrier layers, wherein the at least two carrier layers include: A first carrier layer, wherein the first carrier layer is transparent at least in its optical functional area, and at least one first surface structure is provided on its surface. At least one second carrier layer is fixedly bonded to the first carrier layer, forming at least one first cavity with optical function between the first surface structure of the first carrier layer and the second carrier layer; wherein the first cavity communicates with the external environment of the functional membrane through at least one opening channel, the opening channel being defined by the structure of the first carrier layer, the second carrier layer, or a combination thereof; and the opening channel having at least one opening, the normal direction of the opening plane being set at a horizontal plane or at a first preset angle to the horizontal plane.

2. The functional membrane according to claim 1, characterized in that, The functional membrane includes at least a first set of cavities and a second set of cavities. The first set of cavities extends along a first direction, and the second set of cavities extends along a second direction. The first direction and the second direction are both perpendicular to the thickness direction of the functional membrane, and the first direction and the second direction form a second preset angle.

3. The functional membrane according to claim 2, characterized in that, The surface of the at least one second carrier layer is provided with at least one second surface structure to form at least one second cavity between the second carrier layer and the first carrier layer; and the first set of cavities is formed by the first surface structure, and the second set of cavities is formed by at least one second surface structure.

4. The functional membrane according to claim 3, characterized in that, At least one cavity in the first group of cavities is interconnected with at least one cavity in the second group of cavities to form a three-dimensional open cavity network.

5. The functional membrane according to claim 1, characterized in that, At least one of the openings or the opening channel is provided with a self-cleaning layer or microgrid.

6. The functional membrane according to claim 1, characterized in that, The second carrier layer includes at least one reflective component having at least one reflective surface facing the first carrier layer.

7. The functional membrane according to claim 1, characterized in that, The first carrier layer and / or the second carrier layer contain thermally conductive materials to improve the thermal conductivity of the functional membrane.

8. A photovoltaic module, characterized in that, Includes the functional film and solar cell as described in any one of claims 1-7, wherein the functional film is located on the surface of the solar cell, between two solar cells, and between the solar cell and the module frame.

9. A display device, characterized in that, It includes a functional film and a glass substrate as described in any one of claims 1-7, wherein the functional film is located between two glass substrates or between a glass substrate and a device frame.

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