Foldable Solar Panel

Abstract

The adhesive film layer prevents the flexibility of the connecting conductor from being reduced after hardening, making the connecting conductor less likely to break in the bending section and improving durability. In addition, the isolation layer protects the connecting conductor, thereby reducing the safety risk of the conductor being exposed due to the outer sealing structure of the connecting conductor being broken through. [Solution] The foldable solar panel comprises a power generation layer (100) and two adhesive film layers (200) stacked on opposite sides of the power generation layer (100), the power generation layer (100) having at least two subordinate power generation panels (110) and connecting wires (120), the gap between two adjacent subordinate power generation panels (110) forms a bent section (2000), the two adjacent subordinate power generation panels (110) are electrically connected to each other via the connecting wires (120) passing through the bent section (2000), and an isolation layer (300) is provided between the connecting wires (120) and the adhesive film layer (200).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to a patent application filed in China on March 28, 2023 (application number: 202310314026.2), the entire disclosure of which is incorporated herein by reference. [Technical Field]

[0002] The present invention relates to the technical field of photovoltaic power generation devices, and in particular to foldable solar panels. [Background technology]

[0003] The solar cell panel is an assembly of a plurality of solar cell pieces and is the core of the solar power generation system, and is also the most important part of the solar power generation system.

[0004] A typical example of a portable solar panel is a foldable design, which reduces the volume of the collapsed solar panel and improves portability. A foldable solar panel usually has only one output port, and the generated current is ultimately led to the output port through electrical interconnections between each sub-panel, and then integrated and output. In this case, the electrical connection wires must pass through the folding area. When the product is unfolded or collapsed, the wires located in the folding area are repeatedly unfolded and bent along the folding section.

[0005] Existing foldable solar panels have adhesive films on the top and bottom of the conductors in the folding area. When the foldable solar panel undergoes high-temperature lamination, the adhesive films melt and either encase the conductors in the folding area or seep between the conductors. Because the adhesive films are harder than the conductors after curing, they reduce the flexibility of the conductors, leading to partial or complete breakage of the conductors after hundreds of bends in the bending section. Partially broken conductors increase resistance in that area, causing local overheating and potentially resulting in burnout or fire. Completely broken conductors can cause a disconnection in the product, resulting in the loss of power in the entire product subunit or individual units. Furthermore, conductors that extend beyond the bending section are prone to piercing the sealing material on both sides of the conductors during repeated bending, exposing the conductors and potentially causing electric shock. Summary of the Invention [Problem to be solved by the invention]

[0006] Based on the above description, the present invention proposes a foldable solar panel to prevent the reduction in flexibility of the connecting wires due to the adhesive film layer after curing, making the connecting wires less likely to break at the bending section and improving durability. In addition, the isolation layer protects the connecting wires, thereby reducing the safety risk caused by the exposed wires due to the connecting wires breaking through the outer sealing structure. [Means for solving the problem]

[0007] To achieve this objective, the present application employs the following technical means.

[0008] The foldable solar panel comprises a power generation layer and two adhesive film layers respectively laminated on the front and back sides of the power generation layer, the power generation layer having at least two subsidiary power generation panels and connecting wires, the subsidiary power generation panels being spaced apart, the gaps between adjacent subsidiary power generation panels forming bending sections, the adjacent subsidiary power generation panels being electrically connected to each other via the connecting wires passing through the bending sections, an isolation layer being provided between the connecting wires and the adhesive film layer, the isolation layer covering at least the connecting wires located in the bending sections, thereby isolating the connecting wires located in the bending sections from the adhesive film layers on both sides.

[0009] In one optional technical means of the foldable solar panel, the connecting wires are movably installed relative to the isolation layer, and the connecting wires can move along the radial and / or axial directions relative to the isolation layer; and / or The isolation layer is movably mounted relative to the adhesive film layer, and the isolation layer can move radially and / or axially relative to the adhesive film layer.

[0010] As one optional technical means of the foldable solar panel, the isolation layer is formed into a layered structure, and two isolation layers are arranged, and the two isolation layers are respectively arranged on opposite sides of the connecting wire.

[0011] As an optional technical measure for the foldable solar panel, a ring-shaped enclosure is provided between the two isolation layers, and the edges on both sides of the enclosure are hermetically connected to the two isolation layers, thereby forming an isolation cavity. First relief holes that fit the connecting wires are provided on both ends of the enclosure along the extension direction of the connecting wires, and the connecting wires are drilled into the isolation cavity through the two first relief holes.

[0012] In one optional technical means of the foldable solar panel, the isolation layer is made into a sleeve-like structure, and the connecting wire is drilled through the central through-hole of the isolation layer.

[0013] In one optional technical measure of the foldable solar panel, a blocking section is provided on both ends of the isolation layer along the extension direction of the connecting wire, and the two blocking sections are used to seal both ends of the central through-hole, respectively, and the blocking sections are provided with second relief holes communicating with the central through-hole, the second relief holes are fitted with the connecting wire, and the connecting wire is drilled through the two second relief holes.

[0014] As one optional technical means of the foldable solar panel, the length of the isolation layer along the extension direction of the connecting conductor is greater than the width of the bending section, and both ends of the isolation layer along the extension direction of the connecting conductor are respectively positioned overlapping the subordinate power generating panels on both sides.

[0015] In one technical option for the foldable solar panel, the isolation layer is made of insulating material.

[0016] In one optional technical means of the foldable solar panel, the connecting wire has a flat structure, and the width direction of the connecting wire is perpendicular to the thickness direction of the foldable solar panel.

[0017] As one optional technical means of the foldable solar panel, the foldable solar panel further comprises two thin film layers, each of which is disposed on one side of the two adhesive film layers away from the power generation layer, and the two thin film layers and the power generation layer are respectively bonded via the corresponding adhesive film layers. [Effects of the Invention]

[0018] The beneficial effects of the present invention are as follows:

[0019] In the foldable solar panel according to the present invention, an isolation layer is disposed to isolate the portion of the connecting wire located in the bending section from the adhesive film layers on both sides, thereby preventing the adhesive film layer from adhering to the connecting wire in the bending section, thereby preventing the adhesive film layer from reducing the flexibility of the connecting wire after curing. When the foldable solar panel is folded, the portion of the connecting wire in the bending section can move freely, preventing partial or complete bending of the connecting wire, improving durability. In addition, the isolation layer protects the connecting wire, thereby reducing the safety risk caused by the connecting wire being exposed due to the outer sealing structure of the connecting wire being broken during the bending process, thereby improving safety. [Brief explanation of the drawings]

[0020] In order to more clearly describe the embodiments of the present invention or the technical means in the current technology, we will briefly describe the necessary drawings in the following description of the embodiments or the current technology. It is clear that the drawings in the following description are only a part of the embodiments described in the present invention, and those skilled in the art may obtain other drawings according to these drawings under the premise of not performing creative work. [Figure 1] FIG. 1 is a structural diagram of a foldable solar panel according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a front view of a foldable solar panel according to a first embodiment of the present invention. [Figure 3] FIG. 3 is a schematic diagram showing the stacking structure of the foldable solar panel according to the first embodiment of the present invention. [Figure 4] FIG. 4 is an enlarged view of A in FIG. [Figure 5] FIG. 5 is a schematic diagram showing the local structure of a foldable solar panel according to a second embodiment of the present invention. [Figure 6] FIG. 6 is a schematic diagram showing the local structure of a foldable solar panel according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0021] In order to clarify the technical problems to be solved, the technical means adopted, and the technical effects achieved by the present invention, we will now clearly and completely describe the technical means in the embodiments of the present invention in combination with the drawings in the embodiments of the present invention. It is clear that the described embodiments are only a part of the embodiments of the present invention, and do not represent all the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without performing creative work are also within the scope of protection of the present invention.

[0022] [Example 1] 1-4, the foldable solar panel according to the present invention comprises a power generating layer 100, two adhesive film layers 200, and two thin film layers 600, the two adhesive film layers 200 being disposed on opposite sides of the power generating layer 100, and the two thin film layers 600 being disposed on one side of the two adhesive film layers 200 away from the power generating layer 100, with the two thin film layers 600 being bonded to the power generating layer 100 via the corresponding adhesive film layers 200. The power generating layer 100 has at least two subordinate power generating panels 110 and connecting wires 120, and the subordinate power generating panels 100 are electrically connected to each other via the connecting wires 120. Correspondingly, the foldable solar panel further comprises at least two power generating sections 1000 and a bending section 2000 arranged between adjacent power generating sections 1000, wherein the subordinate power generating panels 110 are located within the power generating sections 1000, the subordinate power generating panels 110 are arranged at intervals, the gaps between adjacent subordinate power generating panels 110 form the above-mentioned bending section 2000, and the adjacent subordinate power generating panels 110 are electrically connected to each other via connecting wires 120 passing through the bending section 2000.

[0023] In this embodiment, as shown in FIG. 1, the power generation layer 100 includes four subordinate power generation panels 110, which are arranged along a straight line, and four power generation sections 1000 are also arranged along a straight line correspondingly.

[0024] Furthermore, as shown in Figures 3 and 4, a spacing layer 300 is provided between the connecting conductor 120 and the adhesive film layer 200, and the spacing layer 300 covers at least the connecting conductor 120 located in the bending section 2000, thereby isolating the connecting conductor 120 located in the bending section 2000 from the adhesive film layers 200 on both sides.

[0025] Specifically, the foldable solar panel according to the present invention has an isolating layer 300 that isolates the portion of the connecting wire 120 located in the bending section 2000 from the adhesive film layers 200 on both sides, preventing the adhesive film layer 200 from adhering to the connecting wire 120 in the bending section 2000. This prevents the adhesive film layer 200 from reducing the flexibility of the connecting wire 120 after curing. When the foldable solar panel is folded, the portion of the connecting wire 120 in the bending section 2000 can move freely, preventing partial or complete breakage of the connecting wire 120. This not only improves durability, but also improves durability by protecting the connecting wire 120, thereby reducing the safety risk caused by the connecting wire 120 being exposed due to the outer sealing structure of the connecting wire 120 being broken during the bending process.

[0026] For example, the subordinate power generating panel 110 includes battery pieces, a support frame, and sealing layers on both sides of the battery pieces, all of which are rigid and cannot bend. In this embodiment, the support frame is made of a material such as epoxy glass fiberboard, and the sealing layer is made of a transparent PET (polyester resin) material. The sealing layer is bonded between the battery pieces and the support frame using a POE (polyolefin elastomer) adhesive film and a PVB (polyvinyl butyral) adhesive film, for example.

[0027] For example, the dependent power generating panel 110 has a plurality of battery segments, which are connected in series and parallel with connecting wires on their surfaces by welding, and the battery segments are crystalline silicon battery segments or non-microcrystalline silicon battery segments. Specifically, the battery segments are PERC (Passivated Emitter and Rear Cell) battery segments, N-type TOPCon (Tunnel Oxide Passivation) battery segments, N-type HJT (Hereto-junction with Intrinsic Thin-layer, crystalline silicon heterojunction) battery segments, IBC (Interdigitated Back Contact) battery segments, or HPBC (Heat-Passivated Contact) battery segments.

[0028] For example, the connecting wire 120 has a flat structure, and the width direction of the connecting wire 120 is perpendicular to the thickness direction of the foldable solar panel. Increasing the width of the connecting wire 120 and decreasing the thickness of the connecting wire 120 reduces the deformation amount of the connecting wire 120 when bending, and increases the tolerance of the connecting wire 120 for bending operations, thereby further reducing the risk of the connecting wire 120 breaking.

[0029] For example, the connecting wire 120 is a woven copper wire, which has excellent elasticity.

[0030] 3, adhesive film layers 200 and thin film layers 600 are disposed through each power generation layer 100 and bending layer. In the power generation section 1000, the front and back sides of the subordinate power generation panel 110 are bonded to the corresponding thin film layers 600 at high temperature and pressure via adhesive film layers 200, respectively, and in the bending section 2000, two adhesive film layers 200 are bonded to each other at high temperature and pressure via two adhesive film layers 200 between them.

[0031] For example, the adhesive film layer 200 may be made of one or more of POE film, EVA (ethylene-vinyl acetate copolymer) film, and PVB film. More preferably, the adhesive film layer 200 may be made of EVA film, which has excellent durability.

[0032] As an example, the connecting wire 120 is movably positioned relative to the isolation layer 300, in other words, no fixed structure is provided between the connecting wire 120 and the isolation layer 300, thereby allowing the connecting wire 120 to move radially and / or axially relative to the isolation layer 300, ensuring the degree of freedom of movement of the connecting wire 120 and allowing the connecting wire 120 to move relative to the isolation layer 300 when the foldable solar panel is folded or unfolded, thereby providing a large range of movement and further reducing the risk of the connecting wire 120 breaking.

[0033] For example, the isolation layer 300 is movably disposed relative to the adhesive film layer 200, i.e., there is no adhesive or other fixed connection between the isolation layer 300 and the adhesive film layer 200, allowing the isolation layer 300 to move radially and / or axially relative to the adhesive film layer 200 and ensuring the freedom of movement of the tether wires 120 within the isolation layer 300, allowing the tether wires 120 to move relative to the adhesive film layer 200 when the foldable solar panel is folded or unfolded, thereby providing a large range of movement and further reducing the risk of breaking the tether wires 120. Specifically, the above arrangement can be achieved by providing a window structure in the adhesive film layer 200 at a position corresponding to the isolation layer 300, and further covering the window structure with a shielding layer made of a non-adhesive material such as nylon to prevent the isolation layer 300 from being exposed.

[0034] For example, the length of the isolation layer 300 along the direction in which the connecting wires 120 extend is greater than the width of the bending section 2000, and both ends of the isolation layer 300 along the direction in which the connecting wires 120 extend are respectively positioned to overlap the subordinate power-generating panels 110 on both sides. On the one hand, the connecting wires 120 in the bending section 2000 are completely covered by the isolation layer 300, improving the reliability of isolating the adhesive film layer 200; on the other hand, when assembling the foldable solar panel, the isolation layer 300 abuts against the subordinate power-generating panels 110 on both sides, which facilitates the positioning and fixing of the isolation layer 300 and improves assembly efficiency and tolerance.

[0035] For example, as shown in FIGS. 3 and 4, the isolation layer 300 is layered, and two isolation layers 300 are arranged on opposite sides of the connecting wire 120, respectively.

[0036] As an example, the isolation layer 300 is made of an insulating material.

[0037] For example, the isolation layer 300 is made of an insulating material with high mechanical toughness, such as an ultra-thin PET (polyethylene terephthalate) film with a thickness of 50 μm to 100 μm, PVC (polyvinyl chloride), silicone, or the like.

[0038] Bending tests were conducted on a foldable solar panel without isolation layer 300 and the foldable solar panel of this embodiment. When the foldable solar panel without isolation layer 300 was bent more than 200 times, resistance increased significantly, when it was bent more than 400 times, leakage occurred in the foldable solar panel, and when it was bent more than 1200 times, the conductors broke. In this embodiment, when the foldable solar panel with isolation layer 300 was bent 3600 times, there was still no increase in resistance, no breakage of the connecting conductors 120, or no exposure of the connecting conductors 120, and the bending strength and safety of the connecting conductors 120 were significantly improved.

[0039] [Example 2] As shown in FIG. 5, based on the first embodiment, the other type of foldable solar panel according to this embodiment differs from the first embodiment in the following points.

[0040] A ring-shaped enclosure member 400 is provided between the two isolation layers 300, and the edges on both sides of the enclosure member 400 are respectively hermetically connected to the two isolation layers 300, thereby forming a barrier cavity 410. First escape holes 420 that fit the connecting wires 120 are provided on both ends of the enclosure member 400 along the extension direction of the connecting wires 120, and the connecting wires 120 are drilled into the barrier cavity 410 through the two first escape holes 420.

[0041] Specifically, the installation of the enclosure member 400 prevents the adhesive of the adhesive film layer 200 from seeping into the gap between the two isolation layers 300 from the ends of the isolation layers 300, and prevents the seeped adhesive from adhering onto the connecting conductor 120 or between the connecting conductor 120 and the isolation layer 300, thereby preventing it from affecting the flexibility and operating space of the connecting conductor 120. This ensures that the connecting conductor 120 maintains its flexibility and has sufficient operating space, improving reliability.

[0042] For example, the inner diameter of the first escape hole 420 is equal to the outer diameter of the connecting wire 120, and the inner wall of the first escape hole 420 is sealed with the connecting wire 120, which further prevents the adhesive of the adhesive film layer 200 from seeping into the barrier cavity 410, resulting in higher reliability.

[0043] In one example, the two isolation layers 300 are integrally formed with the shroud 400 .

[0044] [Example 3] As shown in FIG. 6, based on the first embodiment, the other type of foldable solar panel according to this embodiment differs from the first embodiment in the following points.

[0045] The isolation layer 300 has a sleeve-like structure, and the connecting wire 120 is drilled through a central through-hole 310 of the isolation layer 300. Before connecting the connecting wire 120 to the two subordinate power-generating panels 110, the isolation layer 300 only needs to wrap the connecting wire 120, which simplifies the structure and makes production easier.

[0046] As an example, the radius of the central through-hole 310 is larger than the outer diameter of the tether conductor 120 to ensure that the tether conductor 120 has sufficient operating space within the central through-hole 310 .

[0047] As an example, a blocking portion 500 is provided on both ends of the isolation layer 300 along the extension direction of the connecting conductor 120, and the two blocking portions 500 are used to seal both ends of the central through hole 310, respectively. The blocking portion 500 is provided with a second escape hole 510 communicating with the central through hole 310, and the second escape hole 510 is aligned with the connecting conductor 120, and the connecting conductor 120 is drilled through the two second escape holes 510.

[0048] Specifically, the installation of the blocking portion 500 prevents the adhesive of the adhesive film layer 200 from seeping into the two central through holes 310 from the end of the isolation layer 300, preventing the seeped adhesive from adhering onto the connecting conductor 120 or between the connecting conductor 120 and the isolation layer 300, and preventing it from affecting the flexibility and operating space of the connecting conductor 120. This ensures that the connecting conductor 120 maintains its flexibility and has sufficient operating space, improving reliability.

[0049] For example, the inner diameter of the second escape hole 510 is equal to the outer diameter of the connecting wire 120, and the inner wall of the second escape hole 510 is sealed with the connecting wire 120, which further prevents the adhesive of the adhesive film layer 200 from seeping into the central through hole 310, resulting in higher reliability.

[0050] In one example, the isolation layer 300 is integrally formed with the blocking portion 500 .

[0051] It should be noted that the above is merely a preferred embodiment of the present invention and the principles of the applicable technology. Those skilled in the art should understand that the present invention is not limited to the specific embodiments described herein, and that various obvious modifications, adjustments, and substitutions may be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may also include many other equivalent embodiments without departing from the concept of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. The power generation layer (100) has two adhesive film layers (200) laminated on opposite sides of the power generation layer (100), the power generation layer (100) has at least two subordinate power generation panels (110) and a connecting wire (120), the subordinate power generation panels (110) are arranged at intervals, a gap between two adjacent subordinate power generation panels (110) forms a bent section (2000), and the adjacent two subordinate power generation panels (110) are arranged at intervals. ) are electrically connected to each other via the connecting wires (120) passing through the bending section (2000), and an isolation layer (300) is provided between the connecting wires (120) and the adhesive film layer (200), and the isolation layer (300) covers at least the connecting wires (120) located in the bending section (2000), thereby isolating the connecting wires (120) located in the bending section (2000) from the adhesive film layers (200) on both sides. A foldable solar panel.

2. the tether wire (120) is movably mounted relative to the isolation layer (300), such that the tether wire (120) can move radially and / or axially relative to the isolation layer (300); and / or 2. The foldable solar panel of claim 1, wherein the isolation layer (300) is movably installed relative to the adhesive film layer (200), and the isolation layer (300) can move radially and / or axially relative to the adhesive film layer (200).

3. The isolation layer (300) has a layered structure, two isolation layers (300) are arranged, and the two isolation layers (300) are arranged on opposite sides of the connecting wire (120), respectively.

2. The foldable solar panel according to claim 1.

4. An annular surrounding member (400) is provided between the two isolation layers (300), and both edges of the surrounding member (400) are hermetically connected to the two isolation layers (300), respectively, thereby forming a barrier cavity (410). First relief holes (420) that fit the connecting wires (120) are provided at both ends of the surrounding member (400) along the extending direction of the connecting wires (120), and the connecting wires (120) are drilled into the barrier cavity (410) through the two first relief holes (420).

4. The foldable solar panel according to claim 3.

5. The isolation layer (300) is formed into a sleeve-like structure, and the connecting wire (120) is drilled through a central through-hole (310) of the isolation layer (300).

2. The foldable solar panel according to claim 1.

6. a blocking portion (500) is provided at each end of the isolation layer (300) along the extending direction of the connecting wire (120), and the two blocking portions (500) are used to seal both ends of the central through hole (310), respectively; and a second relief hole (510) communicating with the central through hole (310) is provided in the blocking portion (500), and the second relief hole (510) is aligned with the connecting wire (120), and the connecting wire (120) is drilled through the two second relief holes (510); 6. The foldable solar panel according to claim 5.

7. the length of the isolation layer (300) along the extension direction of the connecting conductor (120) is greater than the width of the bent section (2000), and both ends of the isolation layer (300) along the extension direction of the connecting conductor (120) are arranged to overlap the subordinate power generation panels (110) on both sides, respectively; The foldable solar panel according to any one of claims 1 to 6.

8. Foldable solar panel according to any one of claims 1 to 6, characterized in that the isolation layer (300) is made of an insulating material.

9. The connecting wire (120) has a flat structure, and the width direction of the connecting wire (120) is perpendicular to the thickness direction of the foldable solar panel. The foldable solar panel according to any one of claims 1 to 6.

10. further comprising two thin film layers (600); The two thin film layers (600) are respectively disposed on one side of the two adhesive film layers (200) that are separated from the power generation layer (100), and the two thin film layers (600) and the power generation layer (100) are bonded to each other via the corresponding adhesive film layers (200). The foldable solar panel according to any one of claims 1 to 6.

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