CN101675528B - 用于屋顶的光生伏打模块 - Google Patents

用于屋顶的光生伏打模块 Download PDF

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CN101675528B
CN101675528B CN2007800516210A CN200780051621A CN101675528B CN 101675528 B CN101675528 B CN 101675528B CN 2007800516210 A CN2007800516210 A CN 2007800516210A CN 200780051621 A CN200780051621 A CN 200780051621A CN 101675528 B CN101675528 B CN 101675528B
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B·J·弗莱厄蒂
T·M·戴维
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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Abstract

光生伏打模块(100)在被安装在屋顶上时产生电力。模块(100)被构造为具有粘附到光生伏打层(120)的透明保护上层(110)的层合夹层。将光生伏打层(120)粘附到由纤维增强塑料形成的刚性层(130)上。层合夹层具有围绕周界的框(180、182)。层合板(100)在底面上具有双面胶带的层(200)以将该板粘附到屋顶表面上。

Description

用于屋顶的光生伏打模块
技术领域
本发明涉及用于产生电能的太阳能电池板,并且更具体地涉及集成到安装在平屋顶上的层合的(laminated)、耐候的(weather resistant)夹层(sandwich)中的光生伏打模块。背景技术
用于为住宅和企业产生电力的常规光生伏打板是平坦的并且布置在暴露于太阳下的屋顶的一部分上。过去,这种板被布置在直立在屋顶上以支撑和保护该板的结构上。最近,光生伏打板已经变得能够直接安装在平屋顶上。例如,参见Laaly等人的美国专利申请公开No.2005/0178248A1,其公开了将屋顶膜(roofing membrane)并入板结构中的板。意图将该板安装在具有给下方的结构提供防潮保护以及提供电力的膜的新屋顶或者替换屋顶上。虽然一般适合于屋顶应用,但是附加膜增加了不必要的制造成本并需要在屋顶上安装的附加步骤。发明内容
在此描述的和在附图中示出的光生伏打板使得发电的太阳能电池板能够直接安装在现有屋顶上方的现有平屋顶上。该板被形成为易于用胶带或者其它适合的粘合系统安装的常规的4英尺乘8英尺的板的尺寸和形状。该板不包括膜,并更加易于制造和安装。
根据本发明的优选实施例的方面,光生伏打板包括下部的刚性衬底、具有电输出连接器的中间的光生伏打层和上部的透明保护层。通过热激活的透明的粘合剂(例如乙烯-醋酸乙烯(EVA)),将这些层形成为层彼此固定的层合夹层。这些层和EVA涂层用作层合的光生伏打板的层的粘结剂和衬垫(cushion)。可以用其它适当的粘合剂(例如,聚乙烯醇缩丁醛(polyvinylbuterol,PVB))或者用作粘结剂和衬垫的其它灌封材料(pottantmaterial)来代替EVA。
中间的光生伏打层包括多个电互连的光生伏打电池。例如,中间的光生伏打层有利地包括排列成行和列阵列的160个光生伏打电池。
上部的透明上层优选包括适当厚度的防水、耐化学性的树脂,例如氟化乙烯丙烯(FEP)树脂。这种树脂可从杜邦公司购买,如DuPontTM Teflon
Figure G2007800516210D00021
FEP膜。FEP膜是能够被加热密封、加热成形、真空形成、加热接合等来制造透明上层的透明热塑性膜。在优选实施例中,在固化处理期间使上部的透明层变软以允许透明层的一部分沿着层合结构的侧面形成保护层。
光生伏打板还包括围绕层合夹层的外边缘的外框。优选地,通过硅粘合剂或者其它适当的防水粘合剂将外框固定到层合夹层。在优选的实施例中,通过双面胶带(double-stick tape)的层(例如,具有配方(formulation)为树脂、热塑性塑料和未固化橡胶的自密封带),将刚性衬底的底部固定到现有的屋顶。美国伊利诺斯州Hawthorn Woods的Eternabond公司出售合适的双面胶带,如EternabondTM Double StickTM。附图说明
下面结合附图描述根据本发明实施例的某些方面,其中:
图1示出了层合的光生伏打板的示例性实施例的透视图;
图2示出了沿图1的线2-2得到的图1的光生伏打板的放大的截面图;以及
图3示出了图1的光生伏打板的分解透视图。具体实施方式
如图1、图2和图3所示,层合的光生伏打板100被配置为通常的矩形板,其根据常规建筑材料的尺寸和形状而按尺寸制作和成形。因此,板100能够由施工人员处理,而不需要任何特殊材料处理设备。在工厂或者其它适合的环境中装配板100,使得该板100是完整的且准备好安装在充分暴露于太阳下的平屋顶或者其它位置上。在所示出的实施例中,安装时,板100具有约96英寸(8英尺)乘48英寸(4英尺)的尺寸并且具有小于约0.2英寸的厚度。因此,板100没有给屋顶结构增加显著的高度。虽然不意图用作能行走的表面,但是板100具有足够的结构完整性来承受建筑工人或者屋顶检查员的重量并耐得住落在板100上的物体的撞击。
板100具有面朝上并暴露于太阳下的透明上保护层110。在上保护层110的下方放置中间层120。中间层120包括多个电互连的光生伏打电池122以形成光生伏打阵列。中间层120安置在刚性下层130上。通过下粘合层140将中间层120固定到刚性下层130。通过上粘合层150将中间层120固定到上保护层110。因此中间层120被密封在下粘合层140和上粘合层150之间。
上保护层110为板100提供撞击保护及恶劣天气保护。上保护层110有利地包括DuPontTM Teflon
Figure G2007800516210D00031
氟化乙烯丙烯(FEP)树脂,其被形成为适当厚度(例如,大约0.1英寸)的膜层。因此,使中间层120中的光生伏打电池122暴露于直射的阳光,而不会暴露于湿气和其它气候条件且不会暴露于由脚、落下的物体和碎片引起的直接撞击。具有适当厚度的钢化玻璃也可用作上保护层110。
在所示出的实施例中,刚性下层130包括纤维增强塑料(FRP)。例如,FRP层有利地包括具有嵌入的绞合玻璃纤维的聚酯树脂。在一个优选实施例中,FRP层具有大约0.079英寸的厚度。FRP的刚性下层提供了刚性、轻重量、极低渗透性和平坦性的有利结合。
优选地,提供下粘合层140作为放置在刚性下层130的上表面上的薄膜。然后在下粘合层140上放置中间层120中的光生伏打电池122的阵列。在所示出的实施例中,下粘合层140有利地包括透明粘合剂,例如,乙烯-醋酸乙烯(EVA)。EVA是特别适合于固定电池的透明的热激活的粘合剂。可以用其它适合的粘合剂(例如聚乙烯醇缩丁醛(PVB))或者其它灌封材料来代替EVA。
在下粘合层140上放置光生伏打电池122的阵列之后,在中间层120的上方布置上透明粘合层150使得光生伏打电池122夹在两个透明粘合层之间。上粘合层150应与下粘合层的物理特性相匹配。在所示出的实施例中,上粘合层150和下粘合层140两者都包括EVA,但是可以用其它适当的透明粘合剂来代替EVA。然后在上透明粘合层150的上方放置透明上保护层110以实现在图2中放大的局部截面所示的层合结构。
例如,在Lewis的美国专利No.4,499,658中,描述了EVA材料以及用EVA材料来粘合层合的光生伏打电池的层。除了用作将光生伏打电池122固定在上保护层110和下刚性层130之间的粘结剂之外,上部的EVA层150和下部的EVA层140还用作这两个外层之间的衬垫。
以常规方式的串-并联配置使光生伏打电池122电互连以提供适当的输出电压。例如,在所示出的实施例中,160个光生伏打电池122排列成9行,每行18个电池;然而,最上面的一行去掉了两个电池以提供用于放置接线盒170的空间,接线盒170具有第一耐候的导电体172和第二耐候的导电体174。如图3所示,在被去掉的光生伏打电池的区域中,光生伏打板100包括从中间层120的顶表面伸出来的两个板输出导体176、178。在层合光生伏打板100之后,使该板输出导体176、178中的每一个分别连接到接线盒170内部的耐候的导电体172、174中的一个,如下面所讨论的。
以图2和图3所示的顺序堆叠并对准上保护层110、中间层120、下层160和两个粘合层140和150以形成图1、图2和图3中示出的夹层结构。在层合工艺期间用临时覆盖物(例如,布管(cloth tube)等)覆盖板输出导体176、178中每个的自由端。以已知的方式使用热和压力永久地层合该结构。在一个有利的实施例中,以例如Laaly等人的美国专利申请公开No.2005/0178248A1中描述的方式在真空层合机中层合该结构。尤其是,使该结构首先经受真空以移除EVA粘合剂中任何被俘获的气泡。之后使该结构受到高压以将层尽可能紧地强压在一起。之后将该结构加热到适当的温度(例如,大约160℃)以固化层140和150中的粘合剂从而永久地接合相邻的层。
使层合结构保持足够时间的高温,以固化上透明粘合层150和下透明粘合层140并使这两个透明粘合层粘合在一起以成为完全密封光生伏打电池122的组合层。高温还会使上透明层110变软和流动以提供上述的保护上部涂层。之后允许将层合结构冷却到环境温度。
虽然结果形成的层合结构具有防潮性并且足够坚固以耐受在正常状态下在板100的平常处理期间可能出现的挠曲,但在优选实施例中,为了改善防潮性和结构稳定性,增加了附加的结构元件。尤其是,板100还包括图3示出的耐候的塑料框。在优选实施例中,该框包括第一半框180和第二半框182。这些半框围绕层合结构的边缘放置,如针对第一半框180的图2的截面图所示。这两个半框的暴露端对接在一起以形成围绕板100周界的完整框。虽然示出的是两个分离的半框,但应该理解通过使围绕板100边缘的材料弯曲并使两个自由端对接还可以使用单个长度的框材料。
还如图2所示,半框180、182优选包括具有壁厚度为约0.05英寸的U形截面的塑料压出品(extrusion)。例如,塑料材料有利地包括聚氯乙烯(PVC)、热塑性聚烯烃(TPO)或者其它合适的材料。在所示出的实施例中,U形压出品的两个平行支柱具有从压出品底部内部测量的大约为0.1875英寸的长度。选择U形压出品底部的宽度以适应板100的层合层的厚度。在所示出的实施例中,选择底部的内部宽度为大约0.18英寸。
在所示出的实施例中,每个半框180、182围绕板100外周界的大约一半。还如图2所示,通过适当的粘合层190将每个半框固定到每层的外边缘以及上层110的上表面的一部分和刚性下层130的下表面的一部分。例如,在一个实施例中,粘合层190有利地包括硅粘合剂,其粘性足够强以将半框180、182永久地固定到板100。在板100上放置半框之后,通过胶合或者如所希望的其它适当的方法可将半框180的末端分别固定到半框182的末端。如上面所讨论的,如果使用单一长度的框材料,则框的两个末端可以在单个位置处连接。
在完成层合工艺并且将两个半框180、182固定到板100的边缘之后,以常规的方式(例如,使用硅粘合剂)将接线盒170固定到上层110。当安装接线盒170时,从光生伏打层120伸出来的两个板输出导体176、178穿过接线盒170底部中的孔(未示出)。移除在两个板输出导体176、178上方的临时遮盖物,并使用常规互连器件使两个板输出导体176、178在接线盒170的内部电连接到两个耐候的外部导体172、174。之后将接线盒170的可移动顶部固定在导体互连器件的上方以提供耐候的密封。
如图2和图3所示,安装板100的优选方法包括将胶带层200应用到刚性下层130的底表面上。优选地,胶带层200包括合适的双面胶带,例如,具有配方为树脂、热塑性塑料和未固化橡胶的自密封带。美国伊利诺斯州Hawthorn Woods的Eternabond公司出售合适的自密封双面胶带,如EternabondTM Double StiekTM。双面胶带在两个侧面上都带粘性。当制造时,双面胶带在每个侧面上具有防止粘贴的剥离层(release layer)。有利地在制造板的工艺期间移除一个剥离层。在载运板100之前将胶带层200的暴露的粘合面放置在并粘附到刚性下层130的底表面上。之后,在安装板100期间,移除剩余的剥离层使得板能够粘附到现有屋顶的表面。现有屋顶的表面被清洁并被适当地准备以接收板100。在安装之后,给板100的上层110施加适当的压力以将板永入地粘附到屋顶的表面。在图2中,胶带层200被示出为包括多条窄的胶带(例如,4英寸宽)。还可以得到更宽的胶带以改善制造工艺。
在这里根据本发明的优选实施例公开了本发明,本发明提供了如所附权利要求限定的外部建筑板。在不脱离所附权利要求的预期的精神和范围的情况下,本领域技术人员可以预想到在本发明教导上的各种改变、修改和变更。本发明意图包括这样的改变和修改。

Claims (4)

1.一种光生伏打模块,包括:
包括氟化乙烯丙烯树脂的上透明层;
放置在所述上透明层下方的光生伏打层,所述光生伏打层包括:(i)多个电互连的、布置成矩阵的光生伏打电池,在所述光生伏打层上布置包括这样的区域的空间,在所述区域中电池从所述矩阵中去掉;和(ii)电输出连接器,布置在通过去掉所述电池创建的所述空间上,所述电输出连接器置于所述光生伏打模块与电池的矩阵相同的一侧;
第一层热激活透明粘合剂,其置于所述上透明层和所述光生伏打层之间以将所述光生伏打层粘附到所述上透明层;
放置在所述光生伏打层下方的刚性层;和
第二层热激活透明粘合剂,其置于所述光生伏打层和所述刚性层之间以将所述光生伏打层粘附到所述刚性层。
2.如权利要求1所述的光生伏打模块,其中所述刚性层包括纤维增强塑料。
3.如权利要求1所述的光生伏打模块,还包括粘合层,所述粘合层包括具有第一粘合面和第二粘合面的胶带,所述第一粘合面固定到所述刚性层的下表面,所述第二粘合面具有可剥离的覆盖物,能够移除所述可剥离的覆盖物以将所述粘合层粘附到所述刚性层的下表面,从而将所述光生伏打模块固定到屋顶表面。
4.如权利要求1所述的光生伏打模块,其中所述第一层热激活透明粘合剂和所述第二层热激活透明粘合剂包括乙烯-醋酸乙烯。
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