CN118156345A - Preparation method of graphic layer and preparation method of graphic photovoltaic module - Google Patents

Abstract

The invention relates to a preparation method of a graphic layer and a preparation method of a graphic photovoltaic module, wherein the preparation method of the graphic layer comprises the following steps of (1) preparing a composite film: compounding the bonding layer and the base layer; (2) cutting and welding the cutting layer: covering the cutting layer on the bonding layer of the composite film, and cutting the cutting layer by using laser according to the imaging requirement; (3) waste discharge of the cut layer: the pattern units are preserved and the rest of the dicing layer is removed. The preparation method of the graphical photovoltaic module comprises a graphics layer preparation step and a module typesetting lamination step. The beneficial effects are that: the graphic units can be typeset into the photovoltaic module through the graphic layer with high efficiency and low cost; the material of the graph layer is simple, the preparation process is simple and convenient, the automatic machining can be easily realized, and the production efficiency is greatly improved; meanwhile, the design of the pattern on the molding layer by laser has high flexibility and success rate, and the possibility is provided for the diversity of the imaging components.

Description

Method for preparing graphic layer and method for preparing graphic photovoltaic module

Technical Field

The invention relates to the field of photovoltaic technology, in particular to a method for preparing a graphic layer and a method for preparing a graphic photovoltaic component.

Background technique

The colors of photovoltaic modules have always been common blue and black. Not only are the colors monotonous, but they also lack a certain aesthetic and artistic quality. Whether used in vehicles or buildings, they will affect the aesthetics to a certain extent. Photovoltaic modules with a single blue-black background are increasingly unable to meet people's aesthetic needs. The aesthetic problem of photovoltaic modules has been difficult to solve in history.

With the rise of new energy, more and more photovoltaic modules are used in power generation, building appearance, vehicle appearance, etc., and it is urgent to improve their aesthetics and artistry. The construction field also requires photovoltaic modules to have certain patterns to beautify the urban environment and render urban culture. Artistic graphic photovoltaic modules have positive significance for solar power generation to enter people's lives.

At present, the artistic appearance of photovoltaic modules can be improved by coating and dyeing, but these technologies will greatly affect the power generation efficiency of the modules. This practice of putting the cart before the horse is doomed to fail to meet the long-term needs of the market and society. At the same time, dyeing, coating and other processes will not only cause pollution, but also be relatively complicated in terms of process.

The applicant's Chinese patent document CN115241313A discloses a patterned photovoltaic module and a method for preparing the same. A patterned photovoltaic module is obtained by laying a plurality of pre-processed graphic units, i.e., non-adhesive film units, between the photovoltaic cell layer and the packaging adhesive layer when laying out the photovoltaic module. A low-refractive-index graphic gap space is formed between the graphic units and the photovoltaic cells, forming a pattern on the surface of the photovoltaic module. Compared with the prior art, this solution has lower optical losses and better module performance.

Summary of the invention

The technical problem to be solved by the present invention is to provide a method for preparing a graphic layer and a method for preparing a graphic photovoltaic module, which can efficiently and low-costly layout the graphic units of the graphic photovoltaic module into the photovoltaic module.

The technical solution adopted by the present invention to solve its technical problems is: a method for preparing a graphic layer for graphic photovoltaic modules, comprising the following steps: (1) preparation of a composite film: composite a bonding layer and a base layer to obtain a composite film; (2) cutting and welding a cutting layer: covering the cutting layer on the bonding layer of the composite film, cutting the cutting layer by laser according to the graphic requirements, cutting out graphic units in the cutting layer, and making the edges of the graphic units bonded to the bonding layer; (3) waste removal of the cutting layer: retaining the graphic units and removing the rest of the cutting layer to obtain a graphic layer.

The base layer ensures the stability of the graphic layer, the adhesive layer plays a bonding role, and the graphic units cut out by the cutting layer are used to isolate the adhesive layer and the photovoltaic cell to form a graphic gap space to make the component graphic.

The technical solution of the present invention for patterning photovoltaic modules using a patterned layer is to use the patterned gap space formed in the packaging structure to generate a low refractive index area, the refractive index can be less than or equal to 1, and the low refractive index area and the area normally covered by other adhesive layers will form a large refractive index difference, thereby inducing or enhancing the phenomenon of changing the optical direction of the interface, causing a difference in visual perception, and forming a clear pattern on the surface of the photovoltaic module. At the same time, the low refractive index area absorbs less light, and the power loss of the module is small.

To ensure the power generation efficiency of photovoltaic modules, the graphic layer must be made of transparent materials, and the higher the transmittance, the better. However, transparency does not necessarily mean colorless. In order to meet aesthetic requirements, the color of the graphic unit can be changed to affect the appearance of the module, but it still remains monochrome.

In order to prepare a molding layer with graphic units of different colors and enable the graphic photovoltaic components to form patterns and designs of different colors, it is further defined that in the graphic layer preparation step, by repeating steps (2) and (3), cutting layers of different colors are cut and discharged in sequence on the composite film to obtain a graphic layer with graphic units of different colors on the surface.

Graphic units of different colors present different colors after lamination, which greatly enriches the artistry of the component pattern.

It is further defined that the base layer, cutting layer and adhesive layer are all transparent films, the base layer and cutting layer are non-adhesive film materials under normal temperature and lamination process conditions, and the adhesive layer is an adhesive film material that becomes adhesive by heating.

It is further defined that the material of the base layer is PET, PE, PVDF, PVF, PMMA or PC, the material of the cutting layer is PET or PE, and the material of the bonding layer is EVA.

It is further defined that the base layer and the adhesive layer are compounded together by a laminating machine to form a composite film.

It is further defined that by adjusting the power of the laser, the laser can not only cut through the cutting layer, but also use the heat of the laser to heat and melt the bonding layer at the cutting track to produce a bonding effect, so that the edge of the graphic unit is bonded to the bonding layer.

It is further defined that the cutting track of the laser is a closed line, which is used to make the part of the cutting layer that needs to be removed a whole.

A method for preparing a patterned photovoltaic module includes a graphic layer preparation step and a module layout lamination step. The graphic layer preparation step adopts the above-mentioned graphic layer preparation method to prepare a graphic layer with graphic units on the surface. The graphic units are used to form a graphic gap space in the photovoltaic module to pattern the photovoltaic module. The graphic layer is laid out into the photovoltaic module in the module layout lamination step.

It is further defined that, in the component layout lamination step, the graphic layer is covered on the photovoltaic cell layer in a manner that the graphic units face the photovoltaic cell layer, so as to form a graphic gap space between the graphic units and the photovoltaic cells.

The beneficial effects of the present invention are: the graphic unit can be typeset into the photovoltaic module with high efficiency and low cost through the graphic layer, so that the photovoltaic module is graphicized;

Moreover, the material of the graphic layer is simple, the preparation process is simple, and it can be easily machined and automatically processed, greatly improving production efficiency;

At the same time, designing patterns on the forming layer by laser also has a high degree of flexibility and success rate, and also provides possibilities for the diversity of graphic components.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described below in conjunction with the accompanying drawings and embodiments;

Fig. 1 is a preparation flow chart of Example 1 of the present invention;

FIG2 is a schematic diagram of the layer structure of the graphic layer of the present invention;

FIG3 is a schematic diagram of the layer structure of a patterned photovoltaic module of the present invention;

In the figure, 1. base layer, 2. bonding layer, 3. cutting layer, 3-1. graphic unit, 4. patterned gap space, 5. photovoltaic cell layer, 6. laser, 7. panel, 8. packaging bonding layer, 9. backplane.

Detailed ways

Embodiment 1, as shown in FIG1 , a method for preparing a patterned layer for patterning a photovoltaic module comprises the following steps:

(1) Preparation of composite film: Composite the adhesive layer 2 with the base layer (1) to obtain a composite film;

(2) Cutting and welding of the cutting layer 3: As shown in FIG. 2 , the cutting layer 3 is covered on the bonding layer 2 of the composite film, and the cutting layer 3 is cut according to the patterning requirements by using a laser 6, so that a graphic unit 3-1 is cut out of the cutting layer 3, and the edge of the graphic unit 3-1 is bonded to the bonding layer 2;

(3) Disposal of the cutting layer 3: retain the graphic unit 3-1, remove the remaining part of the cutting layer 3, i.e., the waste part, to obtain the graphic layer.

As shown in FIG1 , a method for preparing a patterned photovoltaic module includes a graphic layer preparation step and a module layout lamination step. The graphic layer preparation step adopts the above-mentioned graphic layer preparation method to prepare a graphic layer having graphic units 3-1 on the surface. The graphic units 3-1 are used to form a graphic gap space 4 in the photovoltaic module to pattern the photovoltaic module. The graphic layer is laid out into the photovoltaic module in the module layout lamination step.

The preparation method of the patterned photovoltaic module is as follows:

(1) Preparation of composite film: The adhesive layer 2 is composited with the base layer 1 to obtain a composite film.

The base layer 1 is a non-adhesive film material under normal temperature and lamination process conditions, and is used to provide a certain stability for the composite film. The adhesive layer 2 is an adhesive film material that becomes sticky when heated. The material of the base layer 1 can be PET, PE, PVDF, PVF, PMMA or PC, etc., and the material of the adhesive layer 2 is EVA, etc.

The step (1) is specifically as follows:

A PET film material is selected as the base layer 1. The thickness of the base layer 1 should not be too thick, and is basically maintained at about 0.05 mm. The plastic particles of the base layer 1 and the bonding layer 2, which are adjusted in a good proportion with the reagent, are melted at high temperature, extruded and formed, and the base layer 1 and the bonding layer 2 are laminated together by a laminating machine to form a composite film. The composite film is rolled up for use. The composite film does not show stickiness at room temperature. The thickness of the bonding layer 2 is 0.04 mm to 0.1 mm.

(2) Cutting and welding of the cutting layer 3: The cutting layer 3 is covered on the adhesive layer 2 of the composite film, and the cutting layer 3 is cut according to the graphic requirements by using a laser 6, so as to cut out a graphic unit 3-1 in the cutting layer 3 and make the edge of the graphic unit 3-1 bond with the adhesive layer 2.

The step (2) is specifically as follows:

Place the prepared composite film on the laser cutting workbench, and keep the adhesive layer 2 facing upward. The purpose of the adhesive layer 2 is to be melted by the laser 6 when the laser 6 cuts the cutting layer 3, thereby producing a bonding effect.

Next, a layer of non-adhesive transparent film material under normal temperature and lamination process conditions is covered on the composite film. This layer of non-adhesive transparent film material is the cutting layer 3, which is tightly attached to the composite film and is ready for cutting by the laser 6. The cutting layer 3 is PET or PE, etc., with a thickness of about 0.05 mm. In order to ensure the simplicity of laser 6 cutting and subsequent work, it is preferred that the cutting layer 3 is as thin as possible, which is convenient for cutting and also makes it easier to tear off the waste when discharging waste.

Subsequently, the cutting layer 3 is completely cut through by the laser 6, and the bonding layer 2 is melted at the cutting track by the heat of the laser 6 to produce a bonding effect. After cooling, the edge of the cutting layer 3 will be bonded to the composite film.

The cutting parameters of laser 6 mainly refer to the power of laser 6. The power of laser 6 should be adjusted in time according to the thickness of cutting layer 3. By adjusting the power of laser 6, laser 6 can not only completely cut through cutting layer 3, so that graphic unit 3-1 and waste discharge part do not affect each other during waste discharge, but also use the heat of laser 6 to heat and melt bonding layer 2 at the cutting track to produce bonding effect, but will not completely cut the graphic layer, thus ensuring the integrity of the graphic layer. Graphic unit 3-1 and waste discharge part will both be bonded to bonding layer 2 at the cutting track, but because there is a non-bonded edge of the waste discharge part, the waste discharge part can be removed by grasping the non-bonded edge of the waste discharge part.

When designing the pattern of the graphic photovoltaic module, since this embodiment relies on forming a graphic gap space 4 between the graphic unit 3-1 and the photovoltaic cell to achieve the graphicization of the module, the pattern should be designed and positioned according to the photovoltaic cell template, and the pattern size should be controlled to ensure that the graphic unit 3-1 does not contact special positions such as the auxiliary grid line of the photovoltaic cell to ensure the stability of the graphic after lamination. At the same time, it should also be ensured that the graphic unit 3-1 is not connected to the waste discharge part of the cutting layer 3, so as to facilitate one-time unified waste discharge, such as designing the cutting track of the cutting layer 3 by the laser 6 as a closed line, so as to make the part of the cutting layer 3 that needs to be removed, that is, the waste discharge part, a whole.

(3) Disposal of the cutting layer 3: retain the graphic unit 3-1, remove the rest of the cutting layer 3, and obtain the graphic layer.

The specific step (3) is as follows: the rest of the cutting layer 3 except the graphic unit 3-1 is the waste part, and the waste part of the cutting layer 3 can be removed by tearing it off. This step can be performed manually or mechanically, and the operation is relatively simple and has high feasibility.

(4) Component layout and lamination.

The step (4) is specifically as follows: as shown in FIG3 , the panel 7, the encapsulation adhesive layer 8, the graphic layer, the photovoltaic cell layer 5, the encapsulation adhesive layer 8, and the back plate 9 are stacked in order to lay out the components, so that the graphic layer is laid out in the photovoltaic component, the graphic layer is located between the encapsulation adhesive layer 8 and the photovoltaic cell layer 5, the panel 7 is glass, the encapsulation adhesive layer 8 is EVA, the photovoltaic cell layer 5 is formed by the photovoltaic cells being electrically connected, and the graphic layer is covered on the photovoltaic cell layer 5 in a manner that the graphic unit 3-1 faces the photovoltaic cell layer 5, so as to form a graphic gap space 4 between the graphic unit 3-1 and the photovoltaic cell. After the layout is completed, it is placed in a laminator for lamination to complete the preparation of the graphic photovoltaic component.

By observing the prepared graphic photovoltaic module, it can be found that the color of the covered area of the graphic unit 3-1 forms a light and dark contrast with the colors of other areas. The covered area of the graphic unit 3-1 presents a light blue color that is obviously brighter than the photovoltaic cell, and an artistic pattern appears on the photovoltaic module.

The laminated components are subjected to power tests, reliability tests, etc. to detect their safety performance. Since the color coating does not block the sunlight, the power generation capacity of the photovoltaic components processed by this solution is guaranteed.

The purpose of patterning the assembly by patterning the gap space 4 of the present invention is to reduce power loss, so the pattern layer will use transparent materials, and the higher the transmittance, the better. The cutting layer 3 is laid and cut once, and the pattern of the prepared patterned photovoltaic assembly is monochrome. However, transparency is not necessarily colorless. In order to meet the aesthetic requirements, Example 1 can also use a colored cutting layer 3 to adjust the color of the pattern of the patterned photovoltaic assembly, but it is still monochrome. When it is necessary to prepare a patterned photovoltaic assembly with various colored patterns, the following Example 2 can be used.

Example 2, a method for preparing a patterned photovoltaic module. Compared with Example 1, Example 2 is basically the same, except that: in the graphic layer preparation step, by repeating steps (2) and (3), cutting layers 3 of different colors are cut and discarded in sequence on the composite film to obtain a graphic layer with graphic units 3-1 of different colors on the surface.

The method for preparing the patterned photovoltaic module of Example 2 comprises the following steps:

(1) Preparation of composite film: The adhesive layer 2 is composited with the base layer 1 to obtain a composite film.

(2) Cutting and welding of the cutting layer 3: The cutting layer 3 is covered on the adhesive layer 2 of the composite film, and the cutting layer 3 is cut according to the graphic requirements by using a laser 6, so as to cut out a graphic unit 3-1 in the cutting layer 3 and make the edge of the graphic unit 3-1 bond with the adhesive layer 2.

(3) Disposal of the cutting layer 3: retain the graphic unit 3-1 and remove the rest of the cutting layer 3.

(4) By repeating steps (2) and (3), the cutting layers 3 of different colors are cut and discarded in sequence on the composite film, thereby obtaining a graphic layer having graphic units 3-1 of different colors on the surface.

By performing steps (2) and (3) once, the cutting and waste removal of a transparent cutting layer 3 of one color is completed. Similar to the plate printing method, transparent cutting layers 3 of different colors are placed in sequence for cutting and waste removal to form graphic units 3-1 of different colors of the composed pattern. Each time a new color cutting layer 3 is cut, a separate waste is removed. For example, after the yellow cutting layer 3 is cut and waste removed, the red cutting layer 3 is cut and waste removed. This cycle is repeated until the arrangement of graphic units 3-1 of all colors on the composite film is completed. Similarly, in principle, the higher the transmittance of the cutting layers 3 of all colors, the better, on the basis of maintaining the color.

(5) Component layout and lamination.

Claims (9)

1. A preparation method of a graphic layer is used for patterning a photovoltaic module and is characterized in that: the method comprises the following steps:

(1) Preparation of a composite film: compounding the bonding layer (2) and the base layer (1) to obtain a composite film;

(2) Cutting and welding the cutting layer (3): covering the cutting layer (3) on the bonding layer (2) of the composite film, cutting the cutting layer (3) by utilizing laser (6) according to the graphical requirement, cutting the graphic unit (3-1) in the cutting layer (3), and bonding the edge of the graphic unit (3-1) with the bonding layer (2);

(3) Waste discharge of the cutting layer (3): the pattern unit (3-1) is reserved, and the rest part of the cutting layer (3) is removed to obtain the pattern layer.

2. The method for preparing a graphic layer according to claim 1, wherein: and (3) cutting and waste discharging the cutting layers (3) with different colors on the composite film sequentially by repeating the step (2) and the step (3) to obtain the pattern layer with the pattern units (3-1) with different colors on the surface.

3. The method for preparing a graphic layer according to claim 1, wherein: the base layer (1), the cutting layer (3) and the bonding layer (2) are all transparent films, the base layer (1) and the cutting layer (3) are non-adhesive film materials under normal temperature and lamination process conditions, and the bonding layer (2) is adhesive film material which shows adhesiveness by heating.

4. A method of producing a graphic layer according to claim 3, characterized in that: the base layer (1) is made of PET, PE, PVDF, PVF, PMMA or PC, the cutting layer (3) is made of PET or PE, and the bonding layer (2) is made of EVA.

5. The method for preparing a graphic layer according to claim 1, wherein: the base layer (1) and the bonding layer (2) are compounded together through a laminating machine.

6. The method for preparing a graphic layer according to claim 1, wherein: the laser (6) can cut the cutting layer (3) by adjusting the power of the laser (6), and the bonding layer (2) can be heated and melted at the cutting track by utilizing the heat of the laser (6) to generate bonding effect, so that the edge of the graphic unit (3-1) and the bonding layer (2) are bonded.

7. The method for preparing a graphic layer according to claim 1, wherein: the cutting track of the laser (6) is a closed line, and the laser is used for enabling the part of the cutting layer (3) to be removed to be a whole.

8. A preparation method of a graphical photovoltaic module is characterized by comprising the following steps: the method comprises a graphics layer preparation step and a component typesetting lamination step, wherein the graphics layer preparation step adopts the graphics layer preparation method of claim 1 to prepare a graphics layer with graphics units (3-1) on the surface, the graphics units (3-1) are used for forming graphical clearance spaces (4) in the photovoltaic component so as to lead the photovoltaic component to be graphical, and the graphics layer is typeset into the photovoltaic component in the component typesetting lamination step.

9. The method for preparing the patterned photovoltaic module according to claim 8, wherein the method comprises the following steps: in the assembly typesetting lamination step, the graphic layer is covered on the photovoltaic cell layer (5) in a mode that the graphic unit (3-1) faces the photovoltaic cell layer (5) and is used for forming a graphic gap space (4) between the graphic unit (3-1) and the photovoltaic cell.