CN105322039B - Ultralight flexible crystalline silicon solar cell modules and preparation method thereof - Google Patents

Abstract

The invention discloses an ultra-light flexible crystalline silicon solar cell component and a preparation method thereof. The ultra-light flexible crystalline silicon solar cell component includes a front film, a solar cell, a supporting material, an encapsulation glue and a back film, and the front film, the encapsulation glue, The solar cell, encapsulant, supporting material and rear mold are arranged in sequence and formed by vacuum thermocompression. The preparation method is: stack the front film, encapsulant, solar cell, encapsulant, support material and rear mold in sequence from top to bottom, under vacuum conditions with a temperature of 100°C to 150°C and a pressure of 15Kpa to 30Kpa , cured for 30 min to 60 min to obtain an ultra-light flexible crystalline silicon solar cell module. The ultra-light flexible crystalline silicon solar cell module of the invention has the advantages of high power generation efficiency, flexibility, light weight, etc., and the preparation method of the invention is integrally formed, and the process is simple.

Description

Ultra-light flexible crystalline silicon solar cell module and preparation method thereof

technical field

The invention belongs to the field of solar cells, in particular to an ultra-light flexible crystalline silicon solar cell component and a preparation method thereof.

Background technique

With the development of the solar photovoltaic industry, photovoltaic power generation is becoming more and more popular. The use of solar power generation in various curved surfaces and low load-bearing environments puts forward higher requirements for the weight and flexibility of components. High-altitude long-endurance airships and long-endurance drones use solar power to provide energy, but they are very sensitive to the weight of solar cells, and conventional solar cells on the market are difficult to meet the requirements. Most of the existing crystalline silicon solar cell modules use glass as the encapsulation material to protect the cells, which is relatively heavy and cannot be bent, which limits its application in some fields. Chinese utility model patent 201120318220.0 discloses an ultra-thin solar cell module, which only changes the glass of the conventional crystalline silicon module into a light-transmitting film, which solves the problem of flexibility of the crystalline silicon module, but the module does not have certain toughness when it is flexible. Solar cells are prone to shattering, causing module failure, and the modules are still heavy with this method. Chinese utility model patent 201220268254.8 discloses a flexible crystalline silicon solar cell module. In addition to replacing the glass with a light-transmitting film, a carbon fiber reinforcement mesh is attached to the back of the module with Wacker E41 adhesive, and the support material is added to the solar cell module. The back of the back, and the support material is not in direct contact with the solar cell, and a layer of material (back film material or back sheet material) is separated in the middle. In this way, the solar cell module and the support material can be bonded directly with glue, and the process implementation It seems simple and convenient, but this method has the following defects: 1. This support structure needs to be coated with a layer of adhesive for bonding, which is a complicated process, and the use of glue increases the weight of solar cell components; 2. The support material protrudes from the sun. The back of the battery module brings a lot of inconvenience to the installation of the solar battery module and limits its application range. Generally, thin-film solar systems such as CIGS and amorphous silicon have low efficiency or high cost, and cannot be industrialized on a large scale.

Contents of the invention

The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art, provide an ultra-light flexible crystalline silicon solar cell module with high power generation efficiency, flexibility, and light weight, and also provide an integrated ultra-light flexible crystalline silicon solar cell module A method for preparing a silicon solar cell module.

In order to solve the problems of the technologies described above, the present invention adopts the following technical solutions:

An ultra-light and flexible crystalline silicon solar cell assembly, including a front film, a solar cell and a support material, and also includes an encapsulation glue and a back film, and the front film, solar cells, support materials, encapsulation glue and the back film are packaged according to the front film, the encapsulation Glue, solar cell, encapsulation glue, support material and rear film are arranged in sequence and vacuum hot pressed to form an ultra-light flexible crystalline silicon solar cell module.

In the above-mentioned ultra-light flexible crystalline silicon solar cell module, preferably, the support material is a fiber grid made of carbon fiber or glass fiber by one-time hot pressing, and the thickness of the support material is ≤0.08mm.

In the aforementioned ultra-light flexible crystalline silicon solar cell module, preferably, the encapsulation adhesive is a hot melt adhesive, and the surface density of the hot melt adhesive is 10 g/m ² -50 g/m ² .

In the above ultra-light flexible crystalline silicon solar cell module, preferably, the hot melt adhesive is polyolefin.

In the above-mentioned ultra-light flexible crystalline silicon solar cell module, preferably, the solar cell is formed by welding a plurality of solar cells in series or in parallel, and the solar cells are monocrystalline silicon solar cells or polycrystalline silicon solar cells.

In the aforementioned ultra-light and flexible crystalline silicon solar cell module, preferably, the thickness of the solar cell sheet is 50 μm to 150 μm.

In the aforementioned ultra-light flexible crystalline silicon solar cell module, preferably, the rear film is a white PET film, and the thickness of the rear film is 20 μm to 30 μm.

In the aforementioned ultra-light flexible crystalline silicon solar cell module, preferably, the front film is an ETFE film or a PET film, and the thickness of the front film is 20 μm to 40 μm.

In the above ultra-light flexible crystalline silicon solar cell module, preferably, the front film is treated with corona.

As a general inventive concept, the present invention also provides a method for preparing the above-mentioned ultra-light and flexible crystalline silicon solar cell module, which includes the following steps: the front film, the solar cell, the support material, and the encapsulant are arranged in the order of front from top to bottom. The sequential lamination of film, encapsulant, solar cell, encapsulant, support material and rear film, first at a temperature of 80°C to 100°C for 1min to 3min, then at a temperature of 100°C to 150°C and a pressure of 15Kpa Under the vacuum condition of ～30Kpa, it is cured for 30min～60min to obtain an ultra-light and flexible crystalline silicon solar cell module.

Compared with the prior art, the present invention has the advantages of:

1. The ultra-light and flexible crystalline silicon solar cell module of the present invention arranges the front film, encapsulant, solar cell group, encapsulant, support material and rear mold in sequence and forms them in one piece by vacuum hot pressing without complicated bonding process, that is, Glue is not required for bonding, which not only simplifies the process, but also reduces the weight of the component. That is to say, the problem of heavy weight and inflexibility of the existing crystalline silicon solar cell components is solved, and at the same time, it has the characteristics of light weight, high strength and good toughness.

2. In the ultra-light flexible crystalline silicon solar cell module of the present invention, the encapsulation glue on the back of the crystalline silicon solar cell has a built-in supporting material, and a rear film is installed after the supporting material, which solves the problem that the supporting material affects the installation and use of the module, and can effectively protect The solar cells are not partially broken, which avoids cracks or failure of the cells, and at the same time, the components can maintain a certain degree of flexibility and bending performance. The support material is placed on the back of the cell, and is formed by the encapsulant at one time, so there is no need to use additional adhesive materials to bond the support material and the cell together, which not only reduces the use of adhesive materials, but also reduces the number of process steps. Reduced component weight.

3. There are the following technical problems in the support material built into the encapsulation adhesive on the back of the solar cell: first, the support material is in direct contact with the solar cell, which may cause the risk of cracking or breaking the solar cell during the encapsulation process; second, the support material may be glued to the encapsulation adhesive There is a risk of loose connection and falling off. In the ultra-light and flexible crystalline silicon solar cell module of the present invention, the support material is made of carbon fiber composite material or glass fiber to form a fiber grid by one-time hot pressing. The contact area between the grid and the encapsulation glue is large, and the bonding strength is firm. Moreover, experiments have confirmed that it is more firmly bonded to polyolefin after encapsulation. The surface of the hot-pressed fiber grid material is smooth, the thickness is within 0.08mm, and the supporting grid material has a certain degree of flexibility, which ensures that the stress generated when the supporting material contacts the solar cells during the packaging process is small and will not cause The solar cell is cracked or broken. In addition, the thermoformed fiber grid has various excellent properties such as light weight, high strength, high modulus, high temperature resistance, corrosion resistance, and fatigue resistance, and meets the support requirements required for flexible solar cells. The shape of the formed fiber grid can be designed in different shapes by making different forming molds according to the bending requirements of the components. The shape can be a hexagon, a matt shape, etc.

4. For the ultra-light and flexible crystalline silicon solar cell module of the present invention, the encapsulating glue is hot-melt glue, and the surface density of the hot-melt glue is between 10-50 g/m2. Utilizing the characteristics of hot melt adhesives melting and solidifying at high temperatures, it is possible to avoid external force on the cells during the encapsulation process and prevent cracks. At the same time, the cured hot melt adhesive has elasticity and flexibility, which can ensure the flexibility of the crystalline silicon solar cell module. Polyolefin is further used in hot melt adhesives. Compared with EVA film (ethylene-vinyl acetate copolymer), polyolefin has greater improvement in environmental aging resistance and component anti-PID performance.

5. In the ultra-light and flexible crystalline silicon solar cell module of the present invention, the solar cell is formed by welding a plurality of monocrystalline silicon or polycrystalline silicon solar cells in series or in parallel, and the silicon used for monocrystalline silicon solar cells or polycrystalline silicon solar cells is After the sheet is thinned, the thickness is about 50 μm to 150 μm (the thickness of the conventional crystalline silicon solar cell is about 200 μm). Not easy to crack. The number of solar cells in the module can be arranged according to the needs of the module, and the size of the solar cells can also be designed according to the needs of the module.

6. In the ultra-light and flexible crystalline silicon solar cell module of the present invention, a back film is arranged on the back of the solar cell module, that is, behind the supporting material, which solves the problem that the supporting material affects the installation and use of the module. In addition, it can also prevent the external environment from affecting the internal battery. piece of damage. The rear film is made of ultra-thin (20μm-30μm) white PET film, which has the characteristics of light weight. At the same time, the white color can reflect light, which can increase the light utilization rate of the solar cell and increase the power generation.

7. The ultra-light flexible crystalline silicon solar cell module of the present invention, the front film is made of ultra-thin (20μm-40μm) ETFE film or PET film, which is light in weight, can be bent arbitrarily, and has high light transmittance and high mechanical strength at the same time . And the front film is treated with corona, which can improve its adhesion ability.

8. The preparation method of the ultra-light and flexible crystalline silicon solar cell module of the present invention first melts the hot melt adhesive at a relatively low temperature, and then solidifies it under high temperature and pressure. It can effectively avoid the problem of cracking of solar cells caused by the flow of hot melt adhesive. The surface density of the prepared ultra-light flexible crystalline silicon solar cell module is within 400g/m ² , the bending radius is less than 0.5m, and the conversion efficiency of the module reaches 16%. The component has strong toughness, will not break and other failure phenomena, and effectively protects the solar cell. Moreover, the ultra-light flexible crystalline silicon solar cell module produced by this structure and process has strong anti-aging performance. After aging for 1000 hours in an environment of 85°C and 85% humidity, it is still intact, and there is no loss of supporting materials. In addition, the welding of solar cells can use ultra-thin and ultra-soft ribbons, the thickness of which is less than 0.1mm, which will greatly reduce the stress on solar cells during the welding process, thereby further reducing the cracks of solar cells.

Description of drawings

Fig. 1 is a schematic structural diagram of an ultra-light flexible crystalline silicon solar cell module according to Example 1 of the present invention.

Fig. 2 is a schematic structural view of the support material in the ultra-light flexible crystalline silicon solar cell module of Example 1 of the present invention.

Explanation of symbols in the figure:

1. Front film; 2. Solar cell; 3. Encapsulation glue; 4. Support material; 5. Back film.

detailed description

The present invention will be further described below in conjunction with the accompanying drawings and specific preferred embodiments, but the protection scope of the present invention is not limited thereby.

Example 1:

An ultra-light and flexible crystalline silicon solar cell assembly, as shown in Figure 1, includes a front film 1, a solar cell 2, a support material 4, an encapsulant 3 and a rear film 5, the front film 1, a solar cell 2, a support material 4, The packaging glue 3 and the back film 5 are arranged in the order of the front film 1, the packaging glue 3, the solar cell 2, the packaging glue 3, the support material 4 and the back film 5, and are vacuum hot pressed to form an ultra-light flexible crystalline silicon solar cell module.

In this embodiment, the encapsulation glue 3 is a hot melt glue with an area density of 30 g/m ² .

In this embodiment, the hot melt adhesive 3 is polyolefin with a thickness of 60 μm.

In this embodiment, the back film 5 is a 25 μm white PET film.

In this embodiment, the front film 1 is a corona-treated ETFE film with a thickness of 25 μm.

In this embodiment, the supporting material 4 is a grid-shaped carbon fiber grid formed by one-time hot pressing of carbon fibers with a thickness of 200 μm, as shown in FIG. 2 .

In this embodiment, the solar cells 2 are formed by welding 4 strings of 10 monocrystalline silicon solar cells in series. The size of the solar cells is 80 mm×40 mm, and the thickness is 150 μm.

A method for preparing the above-mentioned ultra-light flexible crystalline silicon solar cell module, comprising the following steps: the front film 1, the solar cell 2, the support material 4, the encapsulation glue 3 and the rear film 5 are arranged from top to bottom as the front film 1, The encapsulation glue 3, the solar cell 2, the encapsulation glue 3, the support material 4 and the back film 5 are sequentially stacked, first at 90°C, without pressure, for 1min, and then in a vacuum condition with a temperature of 138°C and a pressure of 20Kpa , and cured for 40 minutes to obtain an ultra-light flexible crystalline silicon solar cell module, as shown in Figure 1.

The surface density of the ultra-light flexible crystalline silicon solar cell module prepared in this example is within 400g/m ² , the bending radius is less than 0.5m, and the conversion efficiency of the module reaches 16%. The component has strong toughness, will not break and other failure phenomena, and effectively protects the solar cell. Moreover, the ultra-light flexible crystalline silicon solar cell module produced by this structure and process has strong anti-aging performance. After aging for 1000 hours in an environment of 85°C and 85% humidity, it is still intact, and there is no loss of supporting materials.

The above descriptions are only preferred implementations of the present invention, and the scope of protection of the present invention is not limited to the above examples. All technical solutions under the idea of the present invention belong to the protection scope of the present invention. It should be pointed out that for those skilled in the art, improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

Claims (6)

1. a kind of ultralight flexible crystalline silicon solar cell modules, including cephacoria, solar cell and backing material, it is characterised in that Also include packaging plastic and caudacoria, the cephacoria, solar cell, backing material, packaging plastic and caudacoria are by cephacoria, packaging plastic, the sun Battery, packaging plastic, backing material and caudacoria order arrangement and form ultralight flexible crystal-silicon solar cell group through vacuum hotpressing Part；

The backing material is the fiber rack of carbon fiber or the hot-forming composition of glass fibre primary, the thickness of the backing material Degree≤0.08mm；

The caudacoria is white PET film, and the thickness of the caudacoria is 20 μm~30 μm；

The solar cell is that multiple solar cell pieces are welded in series or in parallel, and the solar cell piece is single Crystal silicon solar battery or polycrystalline silicon solar cell；

The thickness of the solar cell piece is 50 μm~150 μm；

The ultralight flexible crystalline silicon solar cell modules surface density is in 400g/m²Within, bending radius is less than 0.5m.

2. ultralight flexible crystalline silicon solar cell modules according to claim 1, it is characterised in that the packaging plastic is heat Melten gel, the surface density of the PUR is 10 g/m²~50g/m²。

3. ultralight flexible crystalline silicon solar cell modules according to claim 2, it is characterised in that the PUR is poly- Alkene.

4. the ultralight flexible crystalline silicon solar cell modules according to any one of claims 1 to 3, it is characterised in that described Cephacoria is ETFE films or PET film, and the thickness of the cephacoria is 20 μm~40 μm.

5. ultralight flexible crystalline silicon solar cell modules according to claim 4, it is characterised in that the cephacoria is by electricity Dizzy processing.

6. a kind of preparation method of ultralight flexible crystalline silicon solar cell modules as described in any one of Claims 1 to 5, it is special Sign is, comprises the following steps：By cephacoria, solar cell, backing material, packaging plastic according to from top to bottom be cephacoria, packaging plastic, Solar cell, packaging plastic, the order lamination of backing material and caudacoria, first at a temperature of 80 DEG C~100 DEG C, keep 1 min~ 3min, then under the vacuum condition that temperature is 100 DEG C~150 DEG C, pressure is 15Kpa~30Kpa, solidification 30min~ 60min, obtain ultralight flexible crystalline silicon solar cell modules.