CN101984764A - 固定太阳能模件到基底上的体系与方法 - Google Patents
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Abstract
紧固太阳能模件到具有表面不规则物或不均匀度的基底上所使用的隔板，包括位于两层粘合剂层之间的隔板层。该隔板的厚度大于在基底表面上的任何预期的不规则物或不均匀度。隔板由提供充足强度和耐候性的材料组成。
Description
相关申请的交叉参考
本申请要求2008年4月2日提交的美国临时申请No.61/041749的权益。上述申请的公开内容在此通过参考引入。
技术领域
本发明涉及固定(attach)太阳能模件到基底上的体系和方法，和更特别地涉及固定太阳能模件到不均匀的屋顶基底上所使用的自粘附隔板(spacer)。
背景技术
光生伏打太阳能面板或模件通常包括在多个基底之间层压和/或夹在其间的光生伏打电池。大多数光生伏打电池是硬质的晶片-基结晶硅电池或具有在基底上沉积的碲化镉(Cd-Te)、无定形硅或二硒化铜-铟(CuInSe2)的薄膜模件。该薄膜光生伏打模件可以或者硬质或者软质。通过在软质基底上沉积光生伏打层和任何其他所需的层，生成软质薄膜电池和模件。光生伏打电池电连接到彼此上和电连接到其他太阳能面板或模件上，形成集成体系。
光生伏打模件可以直接安装在建筑物的屋顶基底上。然而，许多屋顶基底在足以支持光生伏打模件的大面积上不是平坦的。由于屋顶材料的设计特征，例如加劲的肋条(ribs)、紧固件或其他突出物(它们是屋顶基底的必须组件)导致可产生屋顶基底的不均匀或不规则物。屋顶基底的不均匀物也可来自于辅助操作，例如施加到已有屋顶材料上的涂层，以延长屋顶的寿命或者符合环境主导(initiative)的要求。不均匀或不规则的屋顶基底可使得难以合适地固定光生伏打模件到屋顶基底上并在光生伏打模件上产生非所需的应力点。
因此，本领域需要可操作地紧固太阳能模件到不均匀屋顶基底上的自粘附的隔板。而且，该隔板必须满足耐候性和强度标准，例如抗紫外线曝光，冷冻和解冻循环，雨，雪，冻雨，和冰雹暴露，风的托举力，和极端温度。
发明内容
本发明提供固定太阳能模件到具有表面不规则度或不均匀度的基底上所使用的隔板。该隔板包括隔板层和在隔板层的相对侧上的两层粘合剂层。隔板的厚度大于基底表面上的任何预期的不规则度或不均匀度。隔板由提供充足强度和耐候性的材料组成。
在本发明的一个实例中，提供紧固太阳能模件到屋顶基底上的组装件。屋顶基底包括至少一对平行隔开的屋脊(ridge)。该组装件包括具有顶部表面和底部表面的隔板。该隔板具有小于介于该对屋脊之一和该对屋脊另一个之间距离的第一尺寸，和该隔板具有大于至少一对屋脊的底部和至少一对屋脊顶部之间距离的第二尺寸。第一粘合剂层包括第一表面和第二表面。第一表面与隔板顶部表面的至少一部分接触，和第二表面与太阳能模件的至少一部分接触。第二粘合剂层包括第一表面和第二表面。第一表面与隔板的底部表面的至少一部分接触，和第二表面与屋顶基底的至少一部分接触。该组装件置于至少一对屋脊之间，以便将太阳能模件粘附到屋顶基底上。
在本发明的另一实例中，在隔板的第一侧表面和隔板的第二侧表面之间垂直测量第一尺寸。
在本发明的再一实例中，在隔板的顶部表面和底部表面之间垂直测量第二尺寸。
在本发明的再一实例中，第一粘合剂层完全覆盖隔板的顶部表面，和第二粘合剂层完全覆盖隔板的底部表面。
在本发明的再一实例中，第二粘合剂层粘附到基底上，和第一粘合剂层粘附到太阳能模件上。
在本发明的再一实例中，隔板由乙烯丙烯二烯烃三元共聚物，聚丙烯，或聚氯乙烯中至少一种组成。
在本发明的再一实例中，第一和第二粘合剂层的组成包括未固化的橡胶状聚合物共混物，至少一种增粘剂或固化剂共混物，和聚丁烯均聚物。
在本发明的再一实例中，第一和第二粘合剂层包括存在量为约10％-约60wt％的未固化的橡胶状聚合物共混物，存在量为约5％-约25wt％的至少一种相容的增粘剂，或者存在量为约1％-约5wt％的固化剂共混物，该相容的增粘剂包括酚类增粘剂树脂，固化剂共混物包括固化促进剂，硫活化剂，和固化硫化剂中至少一种，和存在量为约20％-约60wt％的聚丁烯均聚物。
在本发明的再一实例中，隔板包括可拆除地固定到粘合剂层上的剥离衬里。
根据此处提供的说明，进一步的应用领域将变得显而易见。应当理解，说明书和具体实施例拟用于仅仅阐述目的且不打算限制本发明公开内容的范围。
附图说明
图1是位于例举的屋顶基底和例举的太阳能模件之间的根据本发明原理的隔板的实施方案的截面视图；和
图2是根据本发明原理的隔板的实施方案的截面视图。
具体实施方式
下述说明在性质上仅仅是例举且不打算限制本发明的公开内容、应用或用途。
参考图1，阐述了与例举的基底12和例举的太阳能模件14一起使用的根据本发明原理的隔板10。隔板10可操作地固定太阳能模件14到基底12上，正如以下进一步详细地描述的。基底12优选是建筑物的屋顶，但可使用其他基底，且没有脱离本发明的范围。基底12可由各种组合物组成，例如乙烯丙烯二烯烃三元共聚物(EPDM)，热塑性烯烃(TPO)，聚氯乙烯(PVC)，苯乙烯-丁二烯-苯乙烯(SBS)改性的沥青，无规聚丙烯(APP)改性的沥青，镀锌钢，铝，不锈钢，和上漆的钢，所述上漆的钢包括聚偏氟乙烯(PVDF)，即KYNARTM涂覆的钢。基底12包括具有一个或更多个不规则物18的外表面16。在所提供的实例中，不规则物18是规则地间隔的、平行、纵向肋条或在基底12的一部分上延伸的屋脊，然而，在外表面16内可存在各种其他种类的不规则物，其中包括紧固件，其他突出物，和任何其他不均匀的轮廓。
太阳能模件14可具有各种形式，且没有脱离本发明的范围，它通常包括固定到支持基底(未示出)上的至少一个光生伏打电池(未示出)。与本发明一起使用的例举光生伏打电池包括，但不限于，具有碲化镉(Cd-Te)层的薄膜电池，无定形硅，或二硒化铜-铟(CuInSe2)，或包埋在层压膜内的结晶硅片，或沉积在锗或另一基底上的砷化镓。光生伏打电池可操作地由触发(striking)光生伏打电池的太阳光产生电流。支持基底可以由根据其强度和耐候性而选择的任何数量的材料组成。
回到图2，隔板10包括隔板层20，第一粘合剂层22，第二粘合剂层24，第一剥离衬里26，和第二剥离衬里28。隔板层包括顶部表面21和与顶部表面21相对地布置的底部表面23。隔板层20是固体或半固体材料，它足够坚固，以支持太阳能模件14并显示出充足的抗压缩性，以确保在安装过程中，在辊压或挤压太阳能模件14到隔板10的过程中，太阳能模件14与第二粘合剂层24充分接触。隔板层20必须还提供长期的抗环境暴露，当与粘合剂层22、24一起使用时，显示出充足的粘合剂特征，足够结实，以提供抗机械力，例如因风导致的抬举力，和足够挠曲性，以便允许在最接近基底12处的底部表面23与外表面16内的不规则物保形贴合(conform)。隔板层20优选包括选自EPDM、聚丙烯或PVC中的材料。然而，隔板层20可包括显示出所需性能的替代组成，例如聚乙烯、丁腈橡胶、乙烯乙酸乙烯酯、聚苯乙烯、丁基橡胶、新戊二烯橡胶、硅橡胶(silicone)或嵌段共聚物。隔板层20优选是发泡的组合物；然而，也可在没有脱离本发明范围的情况下，使用波纹或固体板材型材。
第一和第二粘合剂层22、24位于隔板层20的相对侧上。粘合剂层22、24可操作地粘附到基底12和太阳能模件14上。第一粘合剂层22包括第一表面25和与第一表面25相对的第二表面27。第一粘合剂层22中的第一表面25与隔板层20的顶部表面21接触，和第一粘合剂层22的第二表面27与太阳能模件14接触。第二粘合剂层24包括第一表面29和与第一表面29相对的第二表面31。第二粘合剂层24中的第一表面29与隔板层20中的底部表面25接触，和第二粘合剂层24中的第二表面31与屋顶基底12接触。
粘合剂层22、24必须由能粘附到以上所述的各种基底12和太阳能模件14上同时显示出所需的耐候性和强度标准，例如抗紫外线曝光，冷冻和解冻循环，雨，雪，冻雨，和冰雹暴露，风的托举力，和极端温度的组合物组成。以下提供例举的组合物：
100.00％
例举组分：
1.Procoil 8240/Sunpar 2280
2.Armco 70
3.Mississippi Lime
4.BNX/Irganox 1010
5.H-300 Poly
6.Mistron
7.29095 Durez，或另一可商购的增粘剂
8.SDG-8650
9.HiSil 233
10 Corax N-650
11.Trilene 65或67，或SDG-8650 Polyisobutylene
12.Nordel IP-4520
13.Efrolen P-85
14.BL/GRN Cure Blend
15.Vulklor
16.Exxpro 3433 or Lanxess 2030
*可允许省去成分7或14之一，只要存在另外那种(非0)即可。
剥离衬里26、28固定到粘合剂层22、24上，且在运输和处理隔板10的过程中可操作地保护粘合剂层22、24。在施加隔板10之前，剥离衬里26、28可操作地从粘合剂层22、24中除去。隔板层20具有设计为它应用到其内的具体应用的第一尺寸或宽度。在隔板层20的第一侧32和隔板层20的第二侧34之间垂直测量第一尺寸。例如，在所提供的实施方案中，隔板层20的宽度大致等于基底12上的不规则物18之间的距离。然而，隔板层20的宽度优选小于或等于相邻的隔开的不规则物18之间的距离。隔板10的长度也可设计为该应用，和例如可在长的辊压片材内提供。隔板层20具有还设计为该应用的第二尺寸或高度或厚度。在隔板层20的顶部表面21和底部表面23之间垂直测量高度。高度优选大于基底12内的任何预期的不均匀度。例如，在所提供的实施方案中，隔板层20具有从顶部表面21到底部表面23测量的高度，它大于从不规则物18的底部到不规则物的顶部测量的不规则物18的高度。
结合参考图1和2，描述使用隔板10，固定太阳能模件14到基底12上的方法。首先，从第一粘合剂层22中除去第一剥离衬里26。然后，在不规则物18之间，在基底12的顶部表面16上挤压或辊压隔板10。或者，隔板10可置于不规则物18之上。如上所述，隔板10的宽度大致与相邻不规则物18之间的距离相配以及高度大于不规则物10的顶部。然后从第二粘合剂层24中除去第二剥离衬里28，以便暴露第二粘合剂层24。最后，在一个或更多个隔板10上挤压或辊压太阳能模件14，并将第二粘合剂层24粘附到太阳能模件10上。使用以上所述的例举的粘合剂组合物，一旦太阳能模件14被安装，则粘合剂层22、24固化。
在替代的实施方案中，没有使用剥离衬里26、28。相反，或者以胶带形式施加第一粘合剂层22到基底12上的不规则物18之间，或者以半液体或液体油漆形式施加。接下来，将隔板层20施加到第一粘合剂层22上，然后，再次以或者胶带或者以半液体或液体油漆形式将第二粘合剂层24施加到隔板层20上。然后，太阳能模件14被紧固到第二粘合剂层24上。在再一实施方案中，第二粘合剂层24可施加到太阳能模件14上或者被与太阳能模件14一体化的粘合剂层替代。
隔板10当在硬质太阳能模件14上的间隔内施加时，允许空气在太阳能模件14和基底12之间，例如在不规则物18和太阳能模件14之间循环。而且，若必须除去或更换太阳能模件14，则可在基底12和太阳能模件14之间容易地切割隔板层20。隔板10还便于太阳能模件14相对于基底12的一定移动，所述移动是由于热或机械诱导的应力导致的。最后，隔板10防止基底12内的轻微的不规则物在太阳能模件10内引起应力。
本发明的描述在性质上仅仅是例举，和没有脱离本发明主旨的各种变化拟落在本发明的范围内。这种变化不被视为脱离本发明的精神与范围。
Claims (14)
1.紧固太阳能模件到屋顶基底上的组装件，该屋顶基底具有至少一对平行隔开的屋脊，该组装件包括：
具有顶部表面和底部表面的隔板，其中隔板具有小于介于该对屋脊之一和该对屋脊另一个之间距离的第一尺寸，和该隔板具有大于至少一对屋脊的底部和至少一对屋脊顶部之间距离的第二尺寸；
具有第一表面和第二表面的第一粘合剂层，其中第一表面与隔板顶部表面的至少一部分接触，和第二表面与太阳能模件的至少一部分接触；
具有第一表面和第二表面的第二粘合剂层，其中第一表面与隔板的底部表面的至少一部分接触，和第二表面与屋顶基底的至少一部分接触；和
其中该组装件置于至少一对屋脊之间，以便将太阳能模件粘附到屋顶基底上。
2.权利要求1的组装件，其中在隔板的第一侧表面和隔板的第二侧表面之间垂直测量第一尺寸。
3.权利要求1的组装件，其中在隔板的顶部表面和底部表面之间垂直测量第二尺寸。
4.权利要求1的组装件，其中第一粘合剂层完全覆盖隔板的顶部表面，和第二粘合剂层完全覆盖隔板的底部表面。
5.权利要求1的组装件，其中第二粘合剂层粘附到基底上，和第一粘合剂层粘附到太阳能模件上。
6.权利要求1的组装件，其中隔板由乙烯丙烯二烯烃三元共聚物，聚丙烯，或聚氯乙烯中至少一种组成。
7.权利要求1的组装件，其中第一和第二粘合剂层的组成包括未固化的橡胶状聚合物共混物，至少一种增粘剂或固化剂共混物，和聚丁烯均聚物。
8.权利要求1的组装件，其中第一和第二粘合剂层包括：
存在量为约10wt％-约60wt％的未固化的橡胶状聚合物共混物，
存在量为约5wt％-约25wt％的至少一种相容的增粘剂，或者存在量为约1wt％-约5wt％的固化剂共混物，其中相容的增粘剂包括酚类增粘剂树脂，固化剂共混物包括固化促进剂，硫活化剂，和固化硫化剂中至少一种，和
存在量为约20wt％-约60wt％的聚丁烯均聚物。
9.将太阳能模件紧固到屋顶基底上的组装件，该屋顶基底具有至少一对平行隔开的屋脊，该组装件包括：
具有顶部表面和底部表面的隔板，其中隔板具有小于介于该对屋脊之一和该对屋脊另一个之间距离的第一尺寸，和该隔板具有大于所述至少一对屋脊的底部和所述至少一对屋脊顶部之间距离的第二尺寸；
具有第一表面和第二表面的第一粘合剂层，其中第一表面与隔板顶部表面的至少一部分接触，和第二表面与太阳能模件的至少一部分接触；
具有第一表面和第二表面的第二粘合剂层，其中第一表面与隔板的底部表面的至少一部分接触，和第二表面与屋顶基底的至少一部分接触；
其中第一和第二粘合剂层各自包括：
存在量为约10wt％-约60wt％的未固化的橡胶状聚合物共混物，
存在量为约5wt％-约25wt％的至少一种相容的增粘剂，或者存在量为约1wt％-约5wt％的固化剂共混物，其中相容的增粘剂包括酚类增粘剂树脂，固化剂共混物包括固化促进剂，硫活化剂，和固化硫化剂中至少一种，和
存在量为约20wt％-约60wt％的聚丁烯均聚物；
其中该组装件置于所述至少一对屋脊之间，以便将太阳能模件粘附到屋顶基底上。
10.权利要求9的组装件，其中在隔板的第一侧表面和隔板的第二侧表面之间垂直测量第一尺寸。
11.权利要求9的组装件，其中在隔板的顶部表面和底部表面之间垂直测量第二尺寸。
12.权利要求9的组装件，其中第一粘合剂层完全覆盖隔板的顶部表面，和第二粘合剂层完全覆盖隔板的底部表面。
13.权利要求9的组装件，其中第二粘合剂层粘附到基底上，和第一粘合剂层粘附到太阳能模件上。
14.权利要求9的组装件，其中隔板由乙烯丙烯二烯烃三元共聚物，聚丙烯，或聚氯乙烯中至少一种组成。
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| DE102008062131A1 (de) * | 2008-12-16 | 2010-06-17 | Tesa Se | Klebeband, insbesondere zur Verklebung optoelektronischer Bauteile |
| US20100205877A1 (en) * | 2009-02-13 | 2010-08-19 | Uday Varde | Mounting system for securing a photovoltaic device and method for its use |
| US8316593B2 (en) * | 2009-03-18 | 2012-11-27 | Garland Industries, Inc. | Solar roofing system |
-
2009
- 2009-04-02 CN CN2009801116892A patent/CN101984764A/zh active Pending
- 2009-04-02 JP JP2011503177A patent/JP5113288B2/ja not_active Expired - Fee Related
- 2009-04-02 US US12/935,842 patent/US8297008B2/en not_active Expired - Fee Related
- 2009-04-02 WO PCT/US2009/039315 patent/WO2009124194A1/en active Application Filing
- 2009-04-02 EP EP09729027.4A patent/EP2321588A4/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| EP2321588A1 (en) | 2011-05-18 |
| EP2321588A4 (en) | 2014-06-18 |
| JP2011517095A (ja) | 2011-05-26 |
| WO2009124194A1 (en) | 2009-10-08 |
| US20110024050A1 (en) | 2011-02-03 |
| US8297008B2 (en) | 2012-10-30 |
| JP5113288B2 (ja) | 2013-01-09 |
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Application publication date: 20110309 |