Curved photovoltaic tile and manufacturing method therefor

Abstract

A curved photovoltaic tile (100) and a manufacturing method therefor. The method comprises: cutting at least one complete cell (11) to obtain a plurality of planar cells (12); electrically connecting the plurality of planar cells (12) to form a planar cell assembly (13); arranging the planar cell assembly (13) on a planar backsheet (14) to obtain a planar module (10); shaping the planar module (10) to obtain a curved module (20); and stacking and fixing the curved module (20) and a curved panel (30) to obtain a curved photovoltaic tile (100), wherein the shape of the curved module (20) is the same as the shape of the curved panel (30).

Description

Curved photovoltaic tiles and their manufacturing methods

[0001] Priority information

[0002] This application claims priority and benefit to patent application No. 202411543525.X, filed with the China National Intellectual Property Administration on October 30, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of photovoltaic technology, and in particular to a curved photovoltaic tile and its manufacturing method. Background Technology

[0004] With the increasing prominence of severe issues such as energy shortages and climate emissions, countries worldwide are paying more and more attention to clean, pollution-free renewable energy sources. Solar energy is an inexhaustible and green energy source. Currently, photovoltaic power generation has a wide range of applications, and building-integrated photovoltaics (BIPV) is gradually becoming a trend, with residential rooftops being the main application area for distributed photovoltaics. Photovoltaic tiles are typically made by laminating tempered glass and solar cells, framing them with an aluminum frame, and sealing the edges with silicone. However, the inventors believe that when flat glass and flat solar cells are laminated to form curved photovoltaic tiles, the solar cells are prone to microcracks, leading to product failure. Summary of the Invention

[0005] This application aims to address at least one of the technical problems existing in the prior art or related technologies.

[0006] Therefore, this application proposes a method for manufacturing curved photovoltaic tiles, comprising:

[0007] At least one complete solar cell is cut to obtain multiple planar solar cells;

[0008] Multiple planar solar cells are electrically connected to form a planar battery assembly;

[0009] The planar cells are arranged as a whole on a planar backplane to obtain a planar module;

[0010] Shape planar components to obtain curved surface components;

[0011] Curved components and curved panels are stacked and fixed to obtain curved photovoltaic tiles, with the shape of the curved components being the same as that of the curved panels.

[0012] Thus, by cutting the complete solar cell, the resulting planar solar cell is smaller in size. When shaping the planar module, the deformation of the planar solar cell on the curved panel can be reduced, thereby lowering the risk of microcracks in the planar solar cell. Furthermore, by first shaping the planar module into a curved module, and then stacking and fixing the curved module to the curved panel, the pressure required for stacking and fixing the curved module and panel to form the curved photovoltaic tile can be reduced. This reduces the overall microcrack phenomenon in the planar solar cells and improves the production yield of the curved photovoltaic tile.

[0013] This application proposes a curved photovoltaic tile, which is manufactured using the above-described manufacturing method.

[0014] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0015] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, wherein:

[0016] Figure 1 is a schematic diagram of the curved photovoltaic tile according to an embodiment of this application;

[0017] Figure 2 is an exploded structural diagram of the curved photovoltaic tile according to an embodiment of this application;

[0018] Figure 3 is a schematic diagram of the curved photovoltaic tile according to an embodiment of this application;

[0019] Figure 4 is a flowchart illustrating the manufacturing method of the curved photovoltaic tile according to an embodiment of this application;

[0020] Figure 5 is a schematic diagram of the manufacturing process of the curved photovoltaic tile according to an embodiment of this application;

[0021] Figure 6 is a schematic diagram of the planar solar cell structure of the curved photovoltaic tile according to an embodiment of this application;

[0022] Figure 7 is a schematic diagram of the planar solar cell structure of the curved photovoltaic tile according to an embodiment of this application;

[0023] Figure 8 is a flowchart illustrating the manufacturing method of curved photovoltaic tiles according to an embodiment of this application.

[0024] Explanation of reference numerals in the attached figures: 100, curved photovoltaic tile; 10, planar module; 11, complete solar cell; 12, planar solar cell; 13, planar solar cell assembly; 14, planar backsheet; 15, first adhesive; 16, encapsulation layer; 20, curved module; 21, curved solar cell assembly; 22, curved backsheet; 30, curved panel; 40, second adhesive. Detailed Implementation

[0025] To better understand the above-mentioned objectives, features, and advantages of this application, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0026] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below.

[0027] Please refer to Figures 1-5. The manufacturing method of the curved photovoltaic tile 100 according to the embodiments of this application includes:

[0028] S10, cut at least one complete solar cell 11 to obtain multiple planar solar cells 12;

[0029] S20, multiple planar solar cells 12 are electrically connected to form a planar solar cell assembly 13;

[0030] S30, the planar battery assembly 13 is arranged on the planar backplate 14 to obtain the planar component 10;

[0031] S40, the planar component 10 is shaped to obtain the curved component 20;

[0032] S50, the curved component 20 and the curved panel 30 are stacked and fixed to obtain the curved photovoltaic tile 100, and the shape of the curved component 20 is the same as the shape of the curved panel 30.

[0033] Thus, by cutting the complete solar cell 11, the resulting planar solar cell 12 is smaller in size. When shaping the planar module 10, the deformation of the planar solar cell 12 on the curved panel 30 can be reduced, thereby reducing the risk of microcracks in the planar solar cell 12. In addition, by obtaining a curved module 10 with the same shape as the curved panel 20, and then stacking and fixing the curved module 20 and the curved panel 30, the pressure required for stacking and fixing the curved module 20 and the curved panel 30 to form the curved photovoltaic tile 100 can be reduced, thereby reducing the microcrack phenomenon of the overall planar solar cell 13 and improving the production yield of the curved photovoltaic tile 100.

[0034] Specifically, the curved photovoltaic tile 100 is a type of roofing tile that converts solar energy into electrical energy. It can be installed on existing roofs or used as a building component, representing a building-integrated photovoltaic (BIPV) application. The curved photovoltaic tile 100 can be used for flat or vertical installations.

[0035] The planar backplate 14 can be made of flexible polymer materials, such as PET, CPC, HPC, etc., so that the planar backplate 14 can be bent into different shapes to suit different design requirements. After shaping the planar backplate 14, a curved backplate 22 can be obtained, and after shaping the planar battery assembly 13, a curved battery assembly 21 can be obtained.

[0036] The curved panel 30 and curved back plate 22 constitute the outermost layer of the curved photovoltaic tile 100, which can seal, insulate, and protect the curved battery assembly 21, thereby improving the mechanical properties of the curved photovoltaic tile 100. The curved panel 30 and curved back plate 22 can protect the curved battery assembly 21 from damage caused by climate change, such as high temperature, low temperature, rain, or hail. They can also protect the curved battery assembly 21 from damage caused by collisions during transportation, effectively improving the curved photovoltaic tile 100's ability to withstand harsh environments.

[0037] The curved panel 30 can be made of a light-transmitting material, such as curved glass, and the light-transmitting curved panel 30 has good light transmittance. The curved panel 30 includes a light-receiving surface and a backlighting surface. The curved panel 30 serves as the front of the curved photovoltaic tile 100. Sunlight can pass through the light-receiving surface of the curved panel 30 to illuminate the curved battery assembly 21, making it easier for the curved battery assembly 21 to receive light and convert solar energy into electrical energy.

[0038] The curved component 20 has the same shape as the curved panel 30. For example, both the curved component 20 and the curved panel 30 are arched or wavy, and the undulation curvature of the connecting surface is consistent.

[0039] The outer layer material on the back of the curved photovoltaic tile 100 is called the curved backsheet 22, which is a key component of the curved photovoltaic tile 100. The curved backsheet 22 isolates the curved battery as a whole 21 from the external environment, achieving insulation and enabling the battery to operate outdoors for a long time. Different structures of curved backsheets 22 have different functions. The appropriate curved backsheet 22 can be selected according to different usage areas. For example, fluorinated backsheets can be used in areas with strong ultraviolet radiation, white backsheets can enhance light reflection and improve power generation efficiency, black backsheets can meet the aesthetic requirements of the roof, and glass backsheets have high light transmittance.

[0040] The complete solar cell 11 is preferably one of the following: XBC, MWT, or shingled solar cells without metal grid lines, where both positive and negative metal electrodes are led out from the back side. A secondary preference is a solar cell with grid lines on both the front and back sides, such as PERC or TOPCON. This maintains the consistency of the overall appearance of the planar solar cell 13, preventing metal grid lines and metal electrodes from affecting the front appearance of the overall planar solar cell 13, thereby improving aesthetics.

[0041] A complete solar cell 11 can be cut into 2, 3, 4, 5 or more planar solar cells 12 using laser slicing technology. Each planar solar cell 12 can be welded normally. Referring to Figures 6 and 7, the planar solar cell 12 in Figure 6 is 1 / 2 of a complete solar cell 11, and the planar solar cell 12 in Figure 7 is 1 / 9 of a complete solar cell 11. The more planar solar cells 12 obtained by cutting a complete solar cell 11, the smaller the size of each planar solar cell 12. When shaping the planar module 10, the deformation of the planar solar cell 12 on the curved panel 30 is smaller, and the risk of microcracks in the planar solar cell 12 is lower.

[0042] The main function of the planar solar cell assembly 13 is to generate electricity. Multiple planar solar cells 12 can be arranged sequentially and then electrically connected. The multiple planar solar cells 12 can be arranged in a rectangular pattern. The planar solar cells 12 can be connected by soldering ribbons, where the back positive (negative) electrode of one planar solar cell 12 is connected to the front negative (positive) electrode of the next planar solar cell 12 and heated together, and so on, connecting all the planar solar cells 12 in series. The planar solar cells 12 can be crystalline silicon solar cells. Crystalline silicon solar cells have relatively low equipment costs, high photoelectric conversion efficiency, and are suitable for generating electricity outdoors under sunlight.

[0043] Please refer to Figure 5. In some embodiments, the width L of the planar solar cell 12 is 20mm-105mm.

[0044] When the width L of the planar solar cell 12 is less than 20 mm, the welding of the planar solar cell 12 is difficult; when the width L of the planar solar cell 12 is greater than 105 mm, the deformation of the planar solar cell 12 on the curved panel 30 is large when shaping the planar module 10, thereby increasing the risk of microcracks in the planar solar cell 12. Therefore, when the width L of the planar solar cell 12 is within the above range, the size of the planar solar cell 12 can be reduced while ensuring that the planar solar cell 12 can be welded normally.

[0045] Specifically, the width L of the planar solar cell 12 can refer to the length of the planar solar cell 12 along the arrangement direction of multiple planar solar cells 12. The width L of the planar solar cell 12 can be 20mm, 35mm, 40mm, 55mm, 60mm, 75mm, 90mm, 105mm, etc. The width L of each planar solar cell 12 can be equal or unequal.

[0046] Referring to Figure 5, in some embodiments, the planar battery assembly 13 is arranged on the planar backplate 14 to obtain the planar assembly 10, including:

[0047] The planar battery assembly 13 is attached to the planar backplate 14 using a first adhesive 15 to form a planar component 10.

[0048] In this way, the first adhesive 15 can bond the planar battery assembly 13 and the planar backplate 14 together, thereby improving the stability and reliability of the planar assembly 10.

[0049] Specifically, the first adhesive 15 can be made of ethylene vinyl acetate (EVA), thermoplastic polyolefin (TPO), polyvinyl butyral (PVB), or polyolefin elastomer (POE) to ensure the encapsulation performance and light transmittance of the first adhesive 15, thereby ensuring the power generation efficiency of the curved photovoltaic tile 100.

[0050] You can first attach the first adhesive 15 to the flat backplate 14, and then attach the flat battery assembly 13 to the first adhesive 15. Alternatively, you can first attach the first adhesive 15 to the flat battery assembly 13, and then attach the flat backplate 14 to the first adhesive 15.

[0051] Referring to Figures 5 and 8, in some embodiments, the planar battery assembly 13 is attached to the planar backplate 14 using a first adhesive 15 to form a planar component 10, including:

[0052] S31, A first adhesive 15 is provided on the flat back plate 14;

[0053] S32, the planar battery assembly 13 is placed on the first adhesive 15;

[0054] S33, the planar battery assembly 13 is pressed together with the planar backplate 14 to form the planar component 10.

[0055] Thus, the planar battery assembly 13 can be attached to the planar backplate 14 through the above steps to form the planar component 10.

[0056] Specifically, a planar laminator can be used to press the planar battery assembly 13 and the planar backplate 14 together to form the planar component 10. In one example, a vacuum environment can be created by evacuating a vacuum device. The planar backplate 14, the first adhesive 15, and the planar battery assembly 13 are placed in sequence, and the planar backplate 14 is pushed by a laminator. For example, the laminator can press the planar backplate 14 flat towards the first adhesive 15 and the planar battery assembly 13 through a flat silicone layer, thereby forming the planar component 10.

[0057] In some embodiments, pressing the planar battery assembly 13 to the planar backplate 14 to form the planar assembly 10 includes:

[0058] The planar battery assembly 13 is pressed and fixed to the planar backplate 14 through a multi-segment pressing method, with the temperature of each segment increasing progressively.

[0059] Thus, by pressing and fixing the planar battery assembly 13 and the planar backplate 14 together in a multi-segment pressing manner to form a planar component 10, the stability of the first adhesive 15 can be improved, which is conducive to forming a stable bond between the planar battery assembly 13 and the planar backplate 14, thereby improving the stability and reliability of the planar component 10.

[0060] The lamination temperature is the temperature applied by the laminator during the lamination process. In one embodiment, the lamination process of laminating the planar battery assembly 13 with the planar backsheet 14 to form the planar component 10 is divided into four stages: the lamination temperature of the first stage is 80°C to 90°C, and the lamination time is 5 mins to 10 mins; the lamination temperature of the second stage is 100°C to 110°C, and the lamination time is 5 mins to 10 mins; the lamination temperature of the third stage is 120°C to 130°C, and the lamination time is 5 mins to 10 mins; and the lamination temperature of the fourth stage is 150°C to 160°C, and the lamination time is 40 mins to 60 mins.

[0061] Referring to Figures 5 and 8, in some embodiments, the planar battery assembly 13 is attached to the planar backplate 14 using a first adhesive 15 to form the planar assembly 10, and further includes:

[0062] S34, an encapsulation layer 16 is provided on the side of the planar battery body 13 that is away from the first adhesive 15.

[0063] Thus, the encapsulation layer 16 can act as a buffer during the shaping of the planar component 10, reducing the risk of the entire planar cell 13 breaking.

[0064] Specifically, the material of the encapsulation layer 16 and the first adhesive 15 can be the same or different. For example, both the encapsulation layer 16 and the first adhesive 15 can be made of EVA material. Or, for example, the encapsulation layer 16 can be made of TPO material and the first adhesive 15 can be made of PVB material.

[0065] Referring to Figure 5, in some embodiments, the planar component 10 is shaped to obtain the curved component 20, including:

[0066] The planar component 10 is pressed at a preset temperature using a shaping fixture to obtain the curved component 20.

[0067] Thus, the planar component 10 is shaped by the shaping tool, so that the shape of the resulting curved component 20 is the same as the shape of the curved panel 30.

[0068] Specifically, the surface shape of the shaping tool can be designed according to the surface shape of the curved panel 30, and the pressure and temperature during shaping can be designed according to the degree of curvature of the curved panel 30 and the materials of each component in the curved assembly 20.

[0069] Referring to Figure 5, in some embodiments, the curved surface component 20 is stacked and fixed to the curved surface panel 30, including:

[0070] A second adhesive 40 and a curved panel 30 are stacked on the side of the curved battery assembly 21 facing away from the curved back plate 22 of the curved component 20, and the curved component 20 and the curved panel 30 are pressed together.

[0071] Thus, the curved component 20 and the curved panel 30 can be connected by the second adhesive 40. In addition, the second adhesive 40 can protect the side of the curved battery assembly 21 away from the curved back plate 22 from hard contact with the curved panel 30, reducing the risk of microcracks in the curved battery assembly 21.

[0072] In one example, a vacuum environment can be created by vacuuming with a vacuum device. A laminator can form a mold with the same shape as the curved component 20 by opening a mold to stably fix the curved component 20. Then, the curved panel 30 is pressed and connected in the direction of the second adhesive 40 and the curved component 20 to form the curved photovoltaic tile 100.

[0073] In some embodiments, pressing the curved surface assembly 20 and the curved surface panel 30 together includes:

[0074] The curved component 20 and the curved panel 30 are pressed and fixed by a multi-segment pressing method, with the pressure of each segment increasing progressively.

[0075] Thus, by pressing the curved component 20 and the curved panel 30 together in a multi-segment pressing manner to form the curved photovoltaic tile 100, the interaction force between the curved component 20 and the curved panel 30 can be increased, thereby improving the stability and reliability of the curved photovoltaic tile 100.

[0076] In one embodiment, the pressing process of fixing the curved component 20 to the curved panel 30 is divided into three stages. The pressing pressure of the first stage is -80 kPa to -70 kPa, and the pressing time is 30 s to 60 s; the pressing pressure of the second stage is -60 kPa to -50 kPa, and the pressing time is 30 s to 60 s; the pressing pressure of the third stage is -40 kPa to 0 kPa, and the pressing time is 15 s to 20 s. The pressing temperature for all three stages is 140℃ to 150℃.

[0077] Please refer to Figure 5. The curved photovoltaic tile 100 of this application embodiment is manufactured using the above-described manufacturing method, which includes:

[0078] S10, cut at least one complete solar cell 11 to obtain multiple planar solar cells 12;

[0079] S20, multiple planar solar cells 12 are electrically connected to form a planar solar cell assembly 13;

[0080] S30, the planar battery assembly 13 is arranged on the planar backplate 14 to obtain the planar component 10;

[0081] S40, the planar component 10 is shaped to obtain the curved component 20;

[0082] S50, the curved component 20 and the curved panel 30 are stacked and fixed to obtain the curved photovoltaic tile 100, and the shape of the curved component 20 is the same as the shape of the curved panel 30.

[0083] Multiple planar solar cells 12 are obtained by cutting the complete solar cell 11, and then the multiple planar solar cells 12 are electrically connected to form a planar solar cell assembly 13. The planar solar cells 12 are small in size, which can reduce the deformation of the planar solar cells 12 on the curved panel 30 when shaping the planar module 10, thereby reducing the risk of microcracks in the planar solar cells 12. In addition, the planar module 10 is formed by pressing the planar back sheet 14, the first adhesive 15 and the planar solar cell assembly 13 together once. Then, the planar module 10 is shaped to form a curved module 20 with the same shape as the curved panel 30. Finally, the curved module 20 and the curved panel 30 are pressed together a second time to form the curved photovoltaic tile 100. Since the shape of the planar solar cell assembly 13 after shaping is the same as the shape of the curved panel 30, the pressure during the second pressing of the curved module 20 and the curved panel 30 can be reduced, thereby reducing the microcrack phenomenon of the curved solar cell assembly 21 and improving the production yield of the curved photovoltaic tile 100.

[0084] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with the described embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0085] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A method for manufacturing curved photovoltaic tiles, wherein, include: At least one complete solar cell is cut to obtain multiple planar solar cells; Multiple planar battery cells are electrically connected to form a planar battery assembly; The planar battery is arranged as a whole on a planar back plate to obtain a planar assembly; The planar component is shaped to obtain a curved surface component; The curved component and the curved panel are stacked and fixed to obtain the curved photovoltaic tile, wherein the shape of the curved component is the same as the shape of the curved panel.

2. The manufacturing method according to claim 1, wherein, The width of the planar solar cell is 20mm-105mm.

3. The manufacturing method according to claim 1, wherein, The step of arranging the planar battery integrally on a planar backplane to obtain a planar assembly includes: The planar battery is attached to the planar backplate with a first adhesive to form the planar assembly.

4. The manufacturing method according to claim 3, wherein, The step of attaching the entire planar battery to the planar backplate using a first adhesive to form the planar assembly includes: The first adhesive is applied to the flat back plate; The planar battery is arranged entirely on the first adhesive; The planar battery is pressed together with the planar backplate to form the planar assembly.

5. The manufacturing method according to claim 4, wherein, The step of pressing the planar battery integrally with the planar backplate to form the planar assembly includes: The planar battery is pressed and fixed to the planar backplate in a multi-stage pressing process, with the temperature of each pressing stage increasing progressively.

6. The manufacturing method according to claim 5, wherein, The pressing temperature for bonding the entire planar battery to the planar backplate is 80℃~160℃.

7. The manufacturing method according to claim 5, wherein, The pressing time for bonding the entire planar battery to the planar backplate is 5 mins to 60 mins.

8. The manufacturing method according to claim 3, wherein, The step of attaching the entire planar battery to the planar backplate using a first adhesive to form the planar assembly further includes: An encapsulation layer is provided on the side of the planar battery that is opposite to the first adhesive.

9. The manufacturing method according to claim 1, wherein, The step of shaping the planar component into a curved component includes: The planar component is pressed at a preset temperature using a shaping fixture to obtain a curved component.

10. The manufacturing method according to claim 1, wherein, The step of stacking and fixing the curved component and the curved panel to obtain the curved photovoltaic tile includes: A second adhesive and a curved panel are stacked on the side of the curved battery assembly that is away from the curved back plate, and the curved assembly and the curved panel are pressed together.

11. The manufacturing method according to claim 10, wherein, The pressing of the curved surface component and the curved surface panel includes: The curved component is pressed and fixed to the curved panel through a multi-segment pressing method, with the pressure of each segment increasing progressively.

12. The manufacturing method according to claim 1, wherein, The pressing pressure for bonding the curved surface component to the curved surface panel is -80 kPa to 0 kPa.

13. The manufacturing method according to claim 1, wherein, The pressing time for pressing and fixing the curved surface component to the curved surface panel is 15s to 60s.

14. The manufacturing method according to any one of claims 1-13, wherein, The planar backplate is made of flexible polymer material.

15. The manufacturing method according to any one of claims 1-14, wherein, The curved panel is made of a light-transmitting material.

16. The manufacturing method according to any one of claims 1-15, wherein, The planar solar cell is a crystalline silicon solar cell.

17. A curved photovoltaic tile, wherein, The curved photovoltaic tile is manufactured using the manufacturing method described in any one of claims 1-16.

18. The curved photovoltaic tile according to claim 17, wherein, The planar backplate is made of flexible polymer material.

19. The curved photovoltaic tile according to claim 17 or 18, wherein, The curved panel is made of a light-transmitting material.

20. The curved photovoltaic tile according to any one of claims 17-19, wherein, The planar solar cell is a crystalline silicon solar cell.

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