CN101906847A - 一种光电幕墙玻璃 - Google Patents
一种光电幕墙玻璃 Download PDFInfo
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Abstract
本发明涉及一种光电幕墙玻璃,由电池板前板TCO玻璃、硅基镀膜、导电膜层、夹胶材料、背板玻璃和接线盒封装组成,其特征在于,所述背板玻璃为钢化玻璃。同时涉及制作所述光电幕墙玻璃的方法。使用本发明制作的光电幕墙玻璃,加工简单、加工程序少、成本低、抗压强度大、并且可以根据需要改变幕墙玻璃的颜色。
Description
技术领域
本发明涉及薄膜电池的新型结构及其制作方法,尤其一种光电幕墙玻璃及其制作方法。
背景技术
光电幕墙玻璃是利用太阳能光电转换原理把光伏技术与建筑领域中的幕墙玻璃材料相互结合制作成的一种新型的光电幕墙玻璃材料,主要应用于建筑领域,可实现光伏技术与建筑楼宇的合理集成。
在目前的薄膜光电幕墙玻璃领域中,现有技术只涉及带边框或者带粘结导轨的组件,对于无边框无导轨的大尺寸薄膜电池组件在抗风压强度上不能达到相应标准要求,且有边框和粘接导轨的薄膜电池组件在BIPV(光伏建筑一体化)领域中存在着一些问题,如成本高,安装不便,颜色单一,不够美观大方,因此,发明一种新型、抗风压强度足够大、颜色可调的无边框薄膜光电幕墙玻璃,是解决大尺寸薄膜电池组件在BIPV、光伏并网电站中应用问题的当务之急。这种组件可以单独在建筑中使用;也可以组合使用,作为幕墙(如中空幕墙)的一种组分。
发明内容
针对现有技术存在的不足本发明提供了一种加工简单、加工程序少、成本低、抗压强度大、美观性好的光电幕墙玻璃。
本发明所述的光电幕墙玻璃由电池板前板TCO玻璃、硅基镀膜、导电膜层、夹胶材料、背板玻璃和接线盒封装组成,背板玻璃为钢化玻璃。所述背板玻璃可以是普通浮法玻璃、工程建筑玻璃或者汽车级钢化玻璃,也可以是单片防火玻璃,在1000℃火焰下耐火时间不低于90分钟,厚度为6-20mm,防火玻璃是在玻璃物理钢化以后再用浸渍法或者喷涂法等化学方法来实现;背板玻璃磨边后进行钢化处理,磨边的倒角可以是半圆或45°,其钢化工艺可以是物理全钢化或物理半钢化或化学钢化;其中全钢化玻璃应力范围是≥95MPa;半钢化玻璃应力范围是24mpa-69Mpa,化学钢化玻璃表面应力范围是330~410MPa。
钢化处理后的钢化玻璃具有很大的表面应力和抗压强度,比普通玻璃高3-4倍,背板玻璃钢化后薄膜电池组件很容易的满足了极限风压和雪压试验。为使本发明有足够得强度,优选前板TCO玻璃,厚度可以为2.8~12.0mm,长度为0.7~3.6m,宽度为0.7~3.6m。
制作本发明所述光电幕墙玻璃,其工序包括:
(1)在玻璃材料上用磁控溅射的方式镀上一层透明导电膜,FTO或AZO或ITO或GAZO;
(2)镀好导电膜的玻璃经过激光划线设备刻出电池分界线;激光划线的宽度为20~200μm;激光划线之间的距离为5~20mm得到TCO前板玻璃;
(3)将刻好线的TCO前板玻璃通过PECVD设备镀上硅基薄膜并激光刻线;
(4)在薄膜上再镀一层导电膜层,可以是氧化锌掺铝层、铝层和镍钒层(不透明),也可以是氧化锌掺铝层、银层和镍钒层(不透明),也可以是透明导电膜(TCO),再次激光刻线;
(5)焊接汇流带;
(6)将背板钢化玻璃和前板镀膜玻璃用高分子夹胶材料粘结在一起,通过高压高温使粘结材料融化以牢固粘结两片玻璃;
(7)焊接接线盒。
上述步骤6可以采用玻璃层压机进行加压粘合,层压过程压力范围是8~15atm,温度范围是120~150℃。也可以采用真空泵抽真空的方式进行预处理,然后送进高压釜进行最后加压。高压釜压力范围是10~14atm,加温范围是130~150℃,时间为3~5小时。
上述前板TCO玻璃的材料可以是普通浮法玻璃,也可以是超白玻璃或者钢化超白玻璃,其导电膜的成分可以是AZO(氧化锌掺铝),也可以是FTO(氧化锡掺氟)或GAZO(掺金属Ga的AZO)或ITO(氧化铟锡)及类似物。
上述硅基薄膜为单结非晶硅薄膜、非晶硅双结薄膜、双结微晶硅薄膜或多结叠层薄膜,其透明度可以为透明或半透明。
上述导电膜层可以是铝镀层、AZO(氧化锌掺铝)、FTO(氧化锡掺氟)、GAZO(掺金属Ga的AZO)、ITO(氧化铟锡)及类似物。
上述夹胶材料成分为高分子夹胶材料,可以是PVB(聚乙烯醇缩丁醛树脂)EVA(乙烯-醋酸乙烯共聚物)或SGP(离子聚合物中间膜)材料。若使用PVB,其厚度为0.38~1.52mm,并且可使用彩色PVB;若使用EVA和SGP,其厚度为0.30~1.50mm。
此外,上述背板玻璃可以通过胶版印刷或丝网印刷工艺印上各种彩釉。这样所得到的光电幕墙玻璃将会呈现出不同的色彩,满足不同用户的需求,同时夹胶材料也可以使用彩色PVB,可以达到同样的效果。
上述接线盒的位置可以在光电幕墙玻璃中间,也可以在边缘位置或置于玻璃外边。同时可以使用胶粘结的方式代替焊接使接线盒与光电幕墙玻璃紧密连接。接线盒内部填充密封胶材料,密封胶可以为硅酮密封胶或聚硫密封胶或聚氨酯密封胶或水基密封胶或高温密封胶或PVC密溶胶。
附图说明
图1:本发明所述光电幕墙玻璃的结构示意图
图2:接线盒位于幕墙玻璃不同位置的示意图,其中:
A为本发明实施例中接线盒位于中央的示意图
B为本发明实施例中接线盒位于边缘的示意图
图3:本发明实施例中接线盒位于组件侧面的示意图
图4:接线盒位于幕墙玻璃不同位置时汇流导电带位置示意图,其中:
A为本发明实施例中接线盒位于中央时汇流导电带位置示意图
B为本发明实施例中接线盒位于边缘时汇流导电带位置示意图
图5:镀膜TCO玻璃微观结构示意图
其中:1-镀膜TCO玻璃、2-夹胶材料、3-背板玻璃、4-接线盒、5-接线盒孔、6-汇流导电带、7-TCO玻璃、8-导电膜层、9-硅基镀膜、10-背电极导电膜层
具体实施方式
下面通过具体实施例对本发明所述方法进行进一步说明。
本专利中涉及的光电幕墙玻璃,由电池板前板TCO玻璃、硅基镀膜、夹胶材料、背板钢化玻璃和接线盒封装组成。
首先,将超白玻璃用磁控溅射的方式镀上一层透明导电膜FTO,镀好导电膜的玻璃经过激光划线设备刻出电池分界线;激光划线的宽度为20μm;激光划线之间的距离为20mm,得到TCO导电玻璃,经过清洗干燥后进入PECVD设备镀上硅基薄膜,镀好膜的薄膜电池板经过激光刻线装置在膜层上刻出微电池的分隔结构;在薄膜上再镀一层导电层,可以是氧化锌掺铝层、铝层和镍钒层(不透明),也可以是氧化锌掺铝层、银层和镍钒层(不透明),也可以是透明导电膜(TCO);然后焊接汇流带,清洗干燥;背板玻璃采用普通浮法玻璃打孔磨边后进行钢化处理,磨边的倒角是45°,背板玻璃中央打直径30mm的圆孔做为接线盒的安装孔,圆孔边缘通过精磨或抛光处理以消除应力,然后进入封装阶段,按照TCO玻璃、硅基镀膜、导电膜层背板玻璃的顺序依次层叠,中间部分填充夹胶材料PVB,使用玻璃层压机对前板镀膜玻璃和背板钢化玻璃进行预加压,层压过程压力为8atm,温度是150℃,使各层组件紧密粘合,粘结好的组件最后使用自动焊接技术焊接接线盒,接线盒在组件的中央位置,接线盒和组件接触处全部密封处理,盒内部也采用密封胶填充。
本发明另一种实施方式:将普通浮法玻璃用磁控溅射的方式镀上一层透明导电膜FTO,镀好导电膜的玻璃经过激光划线设备刻出电池分界线;激光划线的宽度为200μm;激光划线之间的距离为5mm,得到TCO导电玻璃,经过清洗干燥后进入PECVD设备镀上硅基薄膜,镀好膜的薄膜电池板经过激光刻线装置在膜层上刻出微电池的分隔结构;在薄膜上再镀一层导电层,可以是氧化锌掺铝层、铝层和镍钒层(不透明),也可以是氧化锌掺铝层、银层和镍钒层(不透明),也可以是透明导电膜(TCO);然后焊接汇流带,清洗干燥;背板玻璃采用普通浮法玻璃打孔磨边后进行钢化处理,磨边的倒角为半圆形,背板玻璃中央打直径60mm的圆孔做为接线盒的安装孔,圆孔边缘通过精磨或抛光处理以消除应力,然后进入封装阶段,按照TCO玻璃、硅基镀膜、导电膜层背板玻璃的顺序依次层叠,中间部分填充夹胶材料PVB,使用玻璃层压机对前板镀膜玻璃和背板钢化玻璃进行预加压,层压过程压力为9atm,温度是145℃,使各层组件紧密粘合,粘结好的组件最后使用自动焊接技术焊接接线盒,接线盒在组件的中央位置,接线盒和组件接触处全部密封处理,盒内部也采用密封胶填充。
在上述实施例中,激光划线的宽度还可以为120μm;激光划线之间的距离为8mm,层压过程压力也可以是15atm,温度为120℃。
根据需要,接线盒可以安装在组件的边缘位置,背板玻璃的圆孔位置应打在接线盒所要安装的相应位置。
在上述实施例中得到镀好膜的TCO导电玻璃和背板玻璃后,使用另一种方法使其紧密粘合,采用真空泵抽真空的方式进行预处理,然后送进高压釜进行最后加压。高压釜压力是10atm,温度为150℃,加压时间为3小时;或高压釜压力为14atm,温度为140℃,加压3.5小时,或者将高压釜压力调至12atm,加温到150℃,处理5小时。背板玻璃上可以通过胶版印刷或丝网印刷工艺印上各种彩釉,如红色彩釉,使得到的光伏夹胶幕墙玻璃呈现红色。或者将上述夹胶材料改用彩色PVB,同样可使光伏夹胶幕墙玻璃呈现不同的颜色。
Claims (17)
1.一种光电幕墙玻璃,由电池板前板TCO玻璃、硅基镀膜、导电膜层、夹胶材料、背板玻璃和接线盒封装组成,其特征在于,所述背板玻璃为钢化玻璃。
2.如权利要求1所述的一种光电幕墙玻璃,其特征在于,所述的前板TCO玻璃,厚度可以为2.8~12.0mm,长度为0.7~3.6m,宽度为0.7~3.6m;所述背板玻璃可以是普通浮法玻璃、工程建筑玻璃或者汽车级钢化玻璃,也可以是单片防火玻璃,在1000℃火焰下耐火时间不低于90分钟,厚度为6-20mm,防火玻璃是在玻璃物理钢化以后再用浸渍法或者喷涂法等化学方法来实现;背板玻璃磨边后进行钢化处理,磨边的倒角可以是半圆或45°,其钢化工艺可以是物理全钢化或物理半钢化或化学钢化;其中全钢化玻璃应力范围是≥95MPa;半钢化玻璃应力范围是24mpa-69MPa。
3.如权利要求1所述的一种光电幕墙玻璃,其特征在于,所述的前板TCO玻璃的材料可以是普通浮法玻璃,也可以是超白玻璃或者钢化超白玻璃。
4.如权利要求1所述的一种光电幕墙玻璃,其特征在于,所述TCO玻璃的导电膜和所述导电膜层的成分可以是AZO(氧化锌掺铝)或FTO(氧化锡掺氟)或GAZO(掺金属Ga的AZO)或ITO(氧化铟锡)及类似物。
5.如权利要求1所述的一种光电幕墙玻璃,其特征在于,所述硅基薄膜为单结非晶硅薄膜、双结非晶和微晶硅薄膜、双结非晶和非晶硅薄膜或多结叠层薄膜。
6.如权利要求1所述的一种光电幕墙玻璃,其特征在于,所述硅基薄膜电池板可以是不透明或半透明的;其中其中半透明电池板可以通过改变激光刻线位置来调透光度;也可以把不透明背电极材料改为透明电极材料(如AZO、GAZO等)来实现。
7.如权利要求1所述的一种光电幕墙玻璃,其特征在于,所述夹胶材料成分是PVB(聚乙烯醇缩丁醛树脂)或EVA(乙烯-醋酸乙烯共聚物)或SGP(离子聚合物中间膜)材料;使用PVB的厚度为0.38mm~1.52mm,使用EVA或SGP厚度为0.30mm~1.50mm。
8.如权利要求7所述的一种光电幕墙玻璃,其特征在于,夹胶材料PVB可以为彩色透明PVB,厚度可以是0.38mm~1.52mm。
9.如权利要求1或9所述的一种光电幕墙玻璃,其特征在于,背板玻璃可以通过胶版印刷或丝网印刷工艺印上各种彩釉。
10.如权利要求1或2所述的一种光电幕墙玻璃,其特征在于,背板玻璃上可以有供安装接线盒的孔,也可以没有供安装接线盒的孔;有孔时,孔的位置可以位于光电幕墙玻璃组件的中间,也可以位于光电幕墙玻璃组件的顶端。
11.如权利要求1所述的一种光电幕墙玻璃,其特征在于,所述接线盒,其位置可以在所述光电幕墙玻璃组件中间,也可以在边缘位置或置于玻璃侧面。
12.制作如权利要求1所述的一种光电幕墙玻璃,其工序包括:
(1)在玻璃材料上用磁控溅射的方式镀上一层透明导电膜,FTO或AZO或ITO或GAZO;
(2)镀好导电膜的玻璃经过激光划线设备刻出电池分界线;激光划线的宽度为20~200μm;激光划线之间的距离为5~20mm;
(3)将刻好线的TCO导电玻璃通过PECVD设备镀上硅基薄膜并激光刻线;
(4)在薄膜上镀一层导电膜层作为背电极,背电极材料可以是氧化锌掺铝层、铝层和镍钒层(不透明),也可以是氧化锌掺铝层、银层和镍钒层(不透明),也可以是透明导电膜(TCO),再次激光刻线;
(5)焊接汇流带;
(6)将背板钢化玻璃和前板镀膜玻璃用高分子夹胶材料粘结在一起,通过高压高温使粘结材料融化以牢固粘结两片玻璃;
(7)安装接线盒。
13.如权利要求12所述的制作光电幕墙玻璃的方法,所述步骤6,通过高压高温使粘结材料融化以牢固粘结两片玻璃,其特征在于,采用玻璃层压机进行加压粘合,层压过程压力范围是8~15atm,温度范围是120~150℃。
14.如权利要求12所述的制作光电幕墙玻璃的方法,所述步骤6,背板玻璃也可以是单片防火玻璃,在钢化的同时还具有防火的功能;防火温度可达到1000℃,耐火时间≥90分钟。
15.如权利要求12所述的制作光电幕墙玻璃的方法,所述步骤6,通过高压高温使粘结材料融化以牢固粘结两片玻璃,其特征在于,采用真空泵抽真空的方式进行预处理,然后送进高压釜进行最后加压,高压釜压力范围是10~14atm,加温范围是130~150℃,时间为3~5小时。
16.如权利要求12所述的制作光电幕墙玻璃的方法,所述步骤7,安装接线盒,其特征在于,可以使用焊接或胶粘结的方法将接线盒安装到所述光伏夹胶幕墙玻璃上。
17.如权利要求12所述的制作光电幕墙玻璃的方法,其特征在于,所述接线盒内部填充密封胶材料,密封胶可以为硅酮密封胶或聚硫密封胶或聚氨酯密封胶或水基密封胶或高温密封胶或PVC密溶胶。
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