TWM662990U - Photovoltaic module structure - Google Patents

Abstract

A photovoltaic module structure includes: a photovoltaic element and a reflective film structural element, wherein the photovoltaic element is stacked with a first glass substrate, a solar power generation structure and a second glass substrate in sequence; the reflective film structural element is stacked with a glass substrate, an auxiliary layer and a reflective layer in sequence, the reflective layer has a single-layer or multi-layer reflective film, and the reflective film structural element is bonded to the photovoltaic element with a resin to form a photovoltaic module, wherein the first glass substrate and the glass substrate are respectively two outer layers of the photovoltaic module, and the outer surface of the first glass substrate is a light incident surface of the photovoltaic module. Thus, the auxiliary layer with buffering property is used to offset the stress accumulated in the reflective layer during the thermal bending process, thereby avoiding the problem of the reflective layer breaking during the thermal bending process.

Description

Optoelectronic module structure

This invention relates to a photovoltaic module structure, and in particular to a photovoltaic module structure capable of increasing power generation efficiency.

Adding a back reflective film to a photovoltaic module is an effective technology that can effectively improve the photovoltaic conversion efficiency of the photovoltaic module. The photovoltaic module is equipped with a reflective film so that the light that has not been completely absorbed can be reflected back into the solar cell for reabsorption (secondary absorption), thereby improving the photovoltaic conversion efficiency of the solar cell. In various optical and optical element devices, a solar cell module is taken as an example. FIG. 1 is a cross-sectional view of a photovoltaic module of the prior art. Please refer to FIG. 1. The prior art is a reflective film structure element (92) made by combining a double hollow suspension film technology on a photovoltaic element (91). Specifically, the photovoltaic element (91) includes a first glass (911), a solar power generation structure (912) and a second glass (913) stacked in sequence, and then combined with the reflective film structure element (92). The reflective film structure element (92) has a stacked glass substrate (921) and a reflective layer (922). The outer side of the first glass (911) of the photovoltaic element (91) is a light incident surface (911), and light (94) can enter the solar cell module from this. The reflective layer (922) of the prior art in FIG. 1 can actually be composed of a structure in which a reflective film (9222) is provided between two hollow layers (9221). Although the reflective layer (922) of this structure can use the double hollow layers (9221) to block heat conduction and use secondary absorption to increase the reflection/power generation efficiency. However, because the reflective film (9222) is usually made of metal material, it is easy to oxidize and decay, so a double hollow structure with complicated processes is required to protect the reflective layer (922). The process time is extremely long, and it may even take 1 to 2 weeks to complete one piece. However, due to the need for the double hollow structure, the overall structure is very thick, which is not conducive to the production of thin and small sizes.

Due to the difference in heat energy and stress growth between the glass substrate (921) and the reflective layer (922), the coating of the reflective layer (922) will generate residual stress. When a thin film is deposited on the glass substrate (921), the difference in thermal expansion between the glass substrate (921) and the reflective layer (922) will generate thermal stress. Due to the generation of residual stress, the growing reflective layer (922) will have destructive cracks. This is because during the high-temperature deposition process, the thermal tension caused by the temperature is greater than the tensile stress of the reflective layer (922), causing the cracks to grow. A conventional method for solving the above problem is to reduce the growth of cracks by adjusting the process parameter range, but this solution will limit the selection of the material of the reflective layer (922).

In addition, the glass substrate (921) of the above-mentioned optoelectronic module is often installed on a curved surface, so it is necessary to bend the glass substrate (921) into a curved surface or directly produce a curved glass substrate (921). In terms of the bent glass substrate (921), when the glass substrate (921) with the reflective layer (922) is subjected to a thermal bending process, after the glass substrate (921) is thermally bent, when the thermal bending curvature is less than a certain radius, when the glass substrate (921) is bent, the coating layer of the reflective layer (922) does not stretch, so that obvious tension cracks are generated in the coating layer outside the curved surface of the reflective layer (922) of the glass substrate (921), which easily causes the reflective layer (922) to break.

On the other hand, the photovoltaic module of the prior art uses three layers of glass, which will result in the weight and thickness of the entire module cannot be reduced, and the conventional structure does not enhance any reflection effect, nor can it enhance light collection and thus it is difficult to improve the power generation efficiency of the photovoltaic module.

In view of this, the prior art still needs to be improved.

The purpose of this invention is to provide a photoelectric module structure to improve the shortcomings of the prior art.

Another purpose of the present invention is to provide a photoelectric module structure that can improve the performance of the reflective film in resisting cracking during thermal bending.

Another purpose of this invention is to provide a photovoltaic module structure that can increase the reflective effect of the reflective film structure by performing a thermal process after forming the structure, thereby improving the light collection efficiency of the photovoltaic module.

Another purpose of the present invention is to provide a photovoltaic module structure that can reduce the number of glass substrates used (for example, 3 sheets to 2 sheets) and reduce production costs.

Another purpose of this invention is to provide a photovoltaic module structure that can use a low-temperature gluing process to combine a reflective film structure element and a photovoltaic element. The low-temperature gluing process has the effects of low cost, low carbon emissions, and does not cause the solar cell degradation of the photovoltaic element.

To achieve the above and other purposes, the present invention provides a photovoltaic module structure, including: a photovoltaic element, a first glass substrate, a solar power generation structure and a second glass substrate stacked in sequence; and a reflective film structure element, a glass substrate, an auxiliary layer and a reflective layer stacked in sequence, the reflective layer having a single-layer or multi-layer reflective film, the reflective film structure element is bonded to the photovoltaic element with a resin to form a photovoltaic module, the first glass substrate and the glass substrate are respectively the two outermost layers of the photovoltaic module, and the outer surface of the first glass substrate is a light incident surface of the photovoltaic module.

To achieve the above and other purposes, the present invention also provides a photovoltaic module structure, including: a reflective film structural element, a glass substrate, an auxiliary layer and a reflective layer stacked in sequence, the reflective layer having a single layer or multiple layers of reflective film; a solar power generation structure, arranged on a surface of the reflective layer opposite to the auxiliary layer; and a glass, bonded to the surface of the solar power generation structure opposite to the reflective layer with a resin, so that the reflective film structural element, the solar power generation structure and the glass are combined into a photovoltaic module, and the outer surface of the glass is a light incident surface.

In order to achieve the above and other purposes, the present invention also provides a photovoltaic module structure, including: a glass; a solar power generation structure stacked on the glass; and a reflective film structural element, in which a glass substrate, an auxiliary layer and a reflective layer are stacked in sequence, and the reflective layer has a single-layer or multiple-layer reflective film. The reflective film structural element is arranged on the solar power generation structure and is bonded to the surface of the solar power generation structure facing away from the glass with a resin, so that the glass, the solar power generation structure and the reflective film structural element are combined into a photovoltaic module. The glass and the glass substrate are respectively the two outer layers of the photovoltaic module, and the outer surface of the glass is a light incident surface.

In one embodiment, the resin material is polyvinyl acetate copolymer, and the bonding structure of the resin is a solid adhesive layer or a hollow bonding layer.

The directions or similar terms described throughout the present invention, such as front, back, left, right, top, bottom, inside, outside, side, etc., are mainly with reference to the directions of the drawings. Each direction or similar terms are only used to assist in explaining and understanding the various embodiments of the present invention, and are not used to limit the present invention.

The articles used in the elements and components described in the present invention, such as a or the, are only for the convenience of use or simplified description and should be interpreted as including one or at least one, and a single concept also includes a plural concept unless it is obvious that there is a different meaning.

In order to make the above and other purposes, effects, and features more clearly understood, some preferred embodiments are specifically cited below, and detailed descriptions are made with reference to the attached drawings. Without departing from the creative spirit, this case has a variety of implementation methods, and is not limited to the details specifically described in the implementation methods below, and the drawings may not be drawn according to the actual scale, but are provided only for illustrating the embodiments.

FIG2 is a cross-sectional view of a three-piece glass photovoltaic module structure of an embodiment of the present invention. Referring to FIG2, the photovoltaic module structure of the present embodiment comprises a photovoltaic element (10) and a reflective film structure element (20): the photovoltaic element (10) comprises a first glass substrate (11), a solar power generation structure (12) and a second glass substrate (13) stacked in sequence; the reflective film structure element (20) comprises a glass substrate (21), an auxiliary layer (22) and a reflective layer (23) stacked in sequence, wherein the reflective layer ( 23) can be a single-layer or multi-layer reflective film. The reflective film structural element (20) is bonded to the photoelectric element (10) with a resin (30) to form a photoelectric module. The first glass substrate (11) and the glass substrate (21) are respectively the two outermost layers of the photoelectric module. For example, the bottom layer is the first glass substrate (11) and the top layer is the glass substrate (21). The outer surface of the first glass substrate (11) is a light incident surface (111) of the photoelectric module. This embodiment is a three-glass photoelectric module structure having the first glass substrate (11), the second glass substrate (13) and the glass substrate (21). With this structure, the auxiliary layer (22) can provide a buffer for the subsequent thermal bending process, thereby preventing the reflective layer (23) from breaking. In addition, external light (L) can enter the interior of the photovoltaic element (10) through the outside of the light incident surface (111), and convert light energy into electrical energy through the solar power generation structure (12). Moreover, the light (L) that passes through the photovoltaic element (10) and enters the reflective film structure element (20) can be reflected back to the solar power generation structure (12) through the reflective film, so that the solar power generation structure (12) can absorb secondary light reflection, increase the reflection effect, and further improve the power generation efficiency of the photovoltaic module.

FIG3 is a cross-sectional view of a two-piece glass photovoltaic module structure of an embodiment of the present invention. As shown in FIG3, the photovoltaic module structure of the present embodiment comprises a reflective film structural element (40), a solar power generation structure (51) and a glass (52): the reflective film structural element (40) comprises a glass substrate (41), an auxiliary layer (42) and a reflective layer (43) stacked in sequence, the reflective layer (43) having a single layer or multiple layers of reflective film; the solar power generation structure (51) is provided with On a surface of the reflective layer (43) facing away from the auxiliary layer (42); the glass (52) is bonded to the surface of the solar power generation structure (51) facing away from the reflective layer (43) with a resin (60), so that the reflective film structure element (40), the solar power generation structure (51) and the glass (52) are bonded into a photovoltaic module, and the outer surface of the glass (52) is a light incident surface (521). This embodiment is a two-piece glass photovoltaic module structure having the glass (52) and the glass substrate (41). With this structure, the reflective layer (43) disposed on the auxiliary layer (42) can avoid cracking during the thermal bending process. In addition, the external light (L) entering the photovoltaic module structure through the light incident surface (521) can be reflected back to the solar power generation structure (51) through the reflective film structure of the reflective film structural element (40) to absorb the secondary reflected light, thereby further improving the power generation efficiency.

FIG4 is a cross-sectional view of a two-piece glass photovoltaic module structure of another embodiment of the present invention. Referring to FIG4, the photovoltaic module structure of the present embodiment comprises a glass (71), a solar power generation structure (72) and a reflective film structure element (80): the solar power generation structure (72) is stacked on the glass (71), the reflective film structure element (80) is stacked in sequence to form a glass substrate (81), an auxiliary layer (82) and a reflective layer (83), the reflective layer (83) has a single layer or multiple layers of reflective film, the reflective film structure The element (80) is arranged on the solar power generation structure (72), and is bonded to the surface of the solar power generation structure (72) facing away from the glass (71) with a resin (90), so that the glass (71), the solar power generation structure (72) and the reflective film structure element (80) are combined into a photovoltaic module. The glass (71) and the glass substrate (81) are respectively the two outer layers of the photovoltaic module, and the outer surface of the glass (71) is a light incident surface (711). This embodiment is a two-piece glass photovoltaic module structure having the glass (71) and the glass substrate (81). With this structure, the reflective layer (83) arranged on the auxiliary layer (82) can avoid cracking during the thermal bending process. In addition, the external light (L) entering the photovoltaic module structure through the light incident surface (711) can be reflected back to the solar power generation structure (72) through the reflective film structure of the reflective film structural element (80) to absorb secondary light reflection, thereby further improving the power generation efficiency.

Preferably, in the above embodiments, the material of the resin (30, 60, 90) is polyethylene-polyvinyl acetate copolymer, and the layer state of the resin (30, 60, 90) combining the upper and lower structures can be a solid adhesive layer or a hollow bonding layer with a hollow interior.

FIG5 is a flowchart of the manufacturing process steps of the three-piece glass photovoltaic module of an embodiment of the present invention. Please refer to FIG4 and FIG5, this embodiment is a manufacturing method of the structural embodiment of FIG2, and the arrow direction shown on the left side of FIG2 schematically indicates the manufacturing direction of the structure, and the steps include providing a photovoltaic element step (S10), providing a reflective film structure element step (S11) and a combining step (S12): The providing photovoltaic element step (S10) is to stack a first glass substrate, a solar power generation structure and a second glass substrate in sequence to form a photovoltaic element. The step of providing a reflective film structural element (S11) is to stack a glass substrate, an auxiliary layer and a reflective layer in sequence to form a reflective film structural element; the step of combining (S12) is to combine the photoelectric element and the reflective film structural element with a resin so that they are stacked on each other to form a photoelectric module, wherein the outermost layers of the photoelectric module are the first glass substrate and the glass substrate respectively, and the outer surface of the first glass substrate is the light incident surface.

FIG. 6 is a flowchart of the steps of manufacturing a 2-glass optoelectronic module according to an embodiment of the present invention. Please refer to FIG. 3 and FIG. 6 . This embodiment is a manufacturing method of the structural embodiment of FIG. 3 . The arrow direction shown on the left side of FIG. 3 schematically shows the manufacturing direction of the structure. The steps include providing a reflective film structural element step (S20) and forming a photoelectric module step (S21): the providing reflective film structural element step (S20) is to stack a glass substrate, an auxiliary layer and a reflective layer in sequence to form a reflective film structural element; the forming photoelectric module step (S21) is to form a solar power generation structure on the outer surface of the reflective layer, and then to bond a glass with a resin on the outer surface of the solar power generation structure to form a photoelectric module, and the outer surface of the glass is a light incident surface.

FIG. 7 is a flowchart of the manufacturing process steps of a two-glass optoelectronic module according to another embodiment of the present invention. Please refer to FIG. 4 and FIG. 7 . This embodiment is a manufacturing method of the structural embodiment of FIG. 4 . The arrow direction shown on the left side of FIG. 4 schematically shows the manufacturing direction of the structure. The steps include providing a photoelectric element step (S30), providing a reflective film structural element step (S31) and a combining step (S32): the providing a photoelectric element step (S30) is to form a solar power generation structure on a glass surface to form a photoelectric element of a single-sided glass; the providing a reflective film structural element step (S31) is to sequentially stack a glass substrate, an auxiliary layer and a reflective layer; the combining step (S32) is to use a resin to combine the photoelectric element and the reflective film structural element to form a photoelectric module, and the outer layer of the photoelectric module is the glass and the glass substrate.

It is worth mentioning that the embodiments of the photovoltaic module structure and method of the three-piece glass in Figures 2 and 5 of this invention, compared with the previous technology, when performing the heat bending process, due to the effect of the auxiliary layer, the reflective layer is less likely to break, and because the reflective effect of the reflective layer of the photovoltaic module is improved, the photovoltaic module of this invention can absorb secondary light reflection and have a higher power generation efficiency than the previous technology. In addition, compared with the aforementioned embodiments of Figures 2 and 5, the embodiments of the photovoltaic module structure of the two pieces of glass in Figures 3 and 6 are lighter and less expensive because the use of one piece of glass is reduced, but still have a reflective layer that is not easy to break during the heat bending process and a higher power generation efficiency. In addition, compared to the three-glass embodiment of the aforementioned Figures 2 and 5, the two-glass photovoltaic module structure embodiment of the aforementioned Figures 4 and 7 also has a lighter weight, lower cost, a reflective layer that is not easily broken during the thermal bending process, and a higher power generation efficiency. It has better power generation efficiency than the embodiments of Figures 3 and 6. This is because when the solar power generation structure is formed on the reflective layer in the embodiments of Figures 3 and 6, the material of the reflective layer (reflective film) structure is affected, resulting in a decrease in the reflective effect of the reflective film. In contrast, the embodiments of Figures 4 and 7 can combine the reflective film structural elements after the solar power generation structure is formed due to the proper forming sequence, thereby avoiding a decrease in the reflective effect.

Preferably, in each method embodiment, the resin material is polyethylene-polyvinyl acetate copolymer, and the polyethylene-polyvinyl acetate copolymer material is sticky and can be used as an adhesive material. The bonding structure of the resin is a solid adhesive layer or a hollow bonding layer (the adhesive process is simple but has heat conduction problems, the hollow bonding process is more difficult but has low heat conduction, and both processes have their own advantages).

It is worth mentioning that in the present invention, the auxiliary layer (22) of the reflective film structural element (20) is formed on the glass substrate (21) by a plasma sputtering method, and the auxiliary layer (22) material may include silicon dioxide (SiO2), fluorine-doped oxide (FTO), co-doped tin oxide (LFTO), aluminum-doped zinc oxide (AZO), antimony tin oxide (ATO), indium tin oxide (ITO) or indium gallium zinc oxide (IGZO). The auxiliary layer (22) structure has good material properties of flexibility and adhesion. Combined with the plasma sputtering forming process, the auxiliary layer (22) can have a buffering property, which can offset the stress accumulated in the reflective layer (23) during the thermal bending process, and can reduce or even avoid the problem of cracking of the reflective layer during the thermal bending process. Furthermore, the interface between the auxiliary layer and the reflective layer formed by the thermal process can be further optimized, and the auxiliary layer and the reflective layer materials can also be recrystallized, so that the optical reflection effect is improved.

Preferably, the resin bonding process described in each embodiment of the present invention is a low-temperature bonding process of a polyethylene-polyvinyl acetate copolymer (EVA) resin material. It is worth noting that the low-temperature bonding packaging technology of the resin is commonly used in the bonding glass packaging of the solar cell field. Generally, the curing temperature of polyethylene-polyvinyl acetate copolymer is above 130 degrees, and the low-temperature polyethylene-polyvinyl acetate copolymer can be cured below 100 degrees. The cured material has high light transmittance (90%) and can resist ultraviolet rays below 385 nm. Therefore, the advantages of the resin bonding process using a low-temperature bonding process include the advantages of achieving low cost, low carbon emissions, and not causing the degradation of third-generation solar cells.

Preferably, in the above embodiments, the resin material is selected from the group consisting of polyethylene-polyvinyl acetate copolymer (EVA), polyvinyl butyral (PVB), polyolefin elastomer (POE) and thermoplastic elastomer (TPE).

In summary, the features of this invention include: adding an auxiliary layer with buffering properties in the reflective film structure element as a forming base for the reflective film structure to overcome the problem of the reflective film structure element breaking during the thermal bending process. This invention also uses a thermal process to optimize the interface between the auxiliary layer and the reflective layer to further enhance the reflectivity of the reflective film structure element (e.g., a 10% increase), which can improve the power generation efficiency of the photovoltaic module structure used. This invention can also reduce the use of glass in the photovoltaic module structure, which can be reduced to 3 pieces or 2 pieces, but still has the effects of a strong, unbreakable reflective film and high power generation efficiency.

The present invention has been disclosed by using the above preferred embodiments, but they are not used to limit the present invention. Those with ordinary knowledge in the technical field to which the present invention belongs can clearly understand that the present invention is not limited to the details of the above illustrative implementation methods. The implementation methods are only for explaining the present invention, not for limiting the present invention. The present invention is based on the scope of the patent application, not on the above description. The meaning of the scope of the patent application and its equivalent scope are all within the scope of the patent right of the present invention.

[This creation] (10): Photoelectric element (11): First glass substrate (111): Light incident surface (12): Solar power generation structure (13): Second glass substrate (20): Reflection film structure element (21): Glass substrate (22): Auxiliary layer (23): Reflection layer (30): Resin (40): Reflection film structure element (41): Glass substrate (42): Auxiliary layer (43): Reflection layer (51): Solar power generation structure (52): Glass (521): Light incident surface (60): Resin (71): Glass (72): Solar power generation structure (80): Reflection film structure element (81): Glass substrate (82): Auxiliary layer (83): Reflection layer (90): Resin (L): light (S10, S11, S12): step (S20, S21): step (S30, S31, S32): step [Practice] (91): photoelectric element (911): first glass (9111): light incident surface (912): solar power generation structure (913): second glass (92): reflective film structural element (921): glass substrate (922): reflective layer (93): adhesive layer (94): light

Figure 1 is a cross-sectional view of a photovoltaic module of the prior art. Figure 2 is a cross-sectional view of a structure of a 3-glass photovoltaic module of an embodiment of the present invention. Figure 3 is a cross-sectional view of a structure of a 2-glass photovoltaic module of an embodiment of the present invention. Figure 4 is a cross-sectional view of a structure of a 2-glass photovoltaic module of another embodiment of the present invention. Figure 5 is a process flow chart of a 3-glass photovoltaic module of an embodiment of the present invention. Figure 6 is a process flow chart of a 2-glass photovoltaic module of an embodiment of the present invention. Figure 7 is a process flow chart of a 2-glass photovoltaic module of another embodiment of the present invention.

(71): Glass

(711): Light-entering surface

(72):Solar power generation structure

(80):Reflective film structural element

(81): Glass substrate

(82): Auxiliary layer

(83):Reflection layer

(90): Resin

(L):Light

Claims (4)

A photovoltaic module structure comprises: a photovoltaic element (10), on which a first glass substrate (11), a solar power generation structure (12) and a second glass substrate (13) are stacked in sequence; and a reflective film structure element (20), on which a glass substrate (21), an auxiliary layer (22) and a reflective layer (23) are stacked in sequence, the reflective layer (23) having a single-layer or multi-layer reflective film, the reflective film structure element (20) being bonded to the photovoltaic element (10) with a resin (30) to form a photovoltaic module, the first glass substrate (11) and the glass substrate (21) being the two outermost layers of the photovoltaic module, respectively, and the outer surface of the first glass substrate (11) being a light incident surface (111) of the photovoltaic module. A photovoltaic module structure comprises: A reflective film structural element (40) on which a glass substrate (41), an auxiliary layer (42) and a reflective layer (43) are stacked in sequence, wherein the reflective layer (43) has a single-layer or multi-layer reflective film; A solar power generation structure (51) is arranged on a surface of the reflective layer (43) opposite to the auxiliary layer (42); and A glass (52) is bonded to a surface of the solar power generation structure (51) opposite to the reflective layer (43) with a resin (60), so that the reflective film structural element (40), the solar power generation structure (51) and the glass (52) are combined into a photovoltaic module, and the outer surface of the glass (52) is a light incident surface (521). A photovoltaic module structure comprises: a glass (71); a solar power generation structure (72) stacked on the glass (71); and A reflective film structural element (80) is provided with a glass substrate (81), an auxiliary layer (82) and a reflective layer (83) stacked in sequence. The reflective layer (83) has a single-layer or multi-layer reflective film. The reflective film structural element (80) is provided on the solar power generation structure (72) and is bonded to the surface of the solar power generation structure (72) facing away from the glass (71) with a resin (90), so that the glass (71), the solar power generation structure (72) and the reflective film structural element (80) are combined into a photovoltaic module. The glass (71) and the glass substrate (81) are respectively the two outer layers of the photovoltaic module, and the outer surface of the glass (71) is a light incident surface (711). The optoelectronic module structure as described in any one of claims 1 to 3, wherein the material of the resin (30, 60, 90) is polyethylene-polyvinyl acetate copolymer (EVA), and the bonding structure of the resin (30, 60, 90) is a solid adhesive layer or a hollow bonding layer.

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