CN106224877A - 一种风光互补智能led路灯和制备方法 - Google Patents
一种风光互补智能led路灯和制备方法 Download PDFInfo
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- F21S9/02—Lighting devices with a built-in power supply; Systems employing lighting devices with a built-in power supply the power supply being a battery or accumulator
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Abstract
本发明公开一种风光互补智能LED路灯和制备方法，包括灯柱、设在灯柱上的LED灯头、风力发电机组、太阳能电池组件、设在灯柱内的蓄电池和控制器，所述风力发电机组包括设在灯柱顶端的风轮和设在灯柱内的发电机，所述太阳能电池组件设在灯柱上；所述风力发电机组的发电机与太阳能电池组件的输出端与蓄电池连接并同时与控制器数据连接，所述蓄电池对控制器和LED灯头供电。本发明实现风力和太阳能的互补智能发电。
Description
技术领域
本发明属于太阳能电池技术领域，尤其涉及电池片和电池组件生产技术。
背景技术
太阳能电池可以直接将光能转化成电能，越来越受到重视。当前，太阳能电池的电极材料主栅和副栅的主要成分为银，银的成本占太阳能电池总成本的15％左右，消耗巨大且昂贵。降低太阳能电池的制造成本，在对电性能无负面影响的前提下，银浆的使用量降低至关重要。
发明内容
发明目的：针对上述现有存在的问题和不足，本发明的目的是提供一种风光互补智能LED路灯和制备方法，实现风力和太阳能的互补智能发电。
技术方案：为了解决上述技术问题，本发明采用以下技术方案：一种风光互补智能LED路灯，包括灯柱、设在灯柱上的LED灯头、风力发电机组、太阳能电池组件、设在灯柱内的蓄电池和控制器，所述风力发电机组包括设在灯柱顶端的风轮和设在灯柱内的发电机，所述太阳能电池组件设在灯柱上；所述风力发电机组的发电机与太阳能电池组件的输出端与蓄电池连接并同时与控制器数据连接，所述蓄电池对控制器和LED灯头供电；所述太阳能电池组件包括电池片、钢化白玻璃板、EVA胶膜、背板、接线盒、外置聚光透镜、和型材铝框，所述电池片包括硅片和设在硅片正面的银栅线和电极，所述电极为Z字形且与银栅线为垂直设置，通过引线将相邻电池片串并联后连接至接线盒，所述钢化白玻璃和背板分别设在电池片的上下方，且所述钢化玻璃与电池片之间以及背板与电池片之间设有EVA胶膜，所述型材铝框设在设在电池片四周；所述钢化白玻璃板的下表面设有与各电池片相对应的多个聚光凸面，所述外置聚光透镜设在电池片上方，且外置聚光透镜的尺寸为电池板的1.2～1.5倍。
作为优选，所述硅片正面的银栅线通过银浆丝网印刷后经过烧结金属化而成，所述电极为通过二次金属印制的金属丝，所述金属丝与银栅线的接触点之间印刷有导电胶。
作为优选，所述金属丝为铝丝或铜丝。
作为优选，所述银浆有以下重量分数的组分构成：78～90份银粉、2～10份玻璃粉成型物质、2～6份磷酸铁锂、1～5份钛酸四乙酯附着力促进剂，2～3份松油醇、2～3份二甲酸二丁酯、1份磷酸三丁酯、0.1～1份的乙基纤维素、0.5～1.0份PVB30增稠剂 和0.1～0.5份聚酰胺蜡防沉降剂。
作为优选，所述玻璃粉成型物质为40～60％的TeO2、25～40％的P2O5、8～20％的ZnO和5～12％的Bi2O3，且各物质总和为100％的的混合物。
本发明还提供了一种上述风光互补智能LED路灯的制备方法，所述电池片的制备方法包括以下步骤：
1)经过制绒、扩散、后清洗、镀膜和印刷背面电极后的硅片后，首先在硅片正面表面上通过银浆丝网印刷多条银栅线，烘干后送入烧结炉中进行烧结金属化处理；
2)金属化处理后的硅片经过冷却送入活化箱，在携带二元酸气体的惰性气体作用下进行吹扫活化，温度控制在140～200℃，停留时间为10～45s，二元酸气体流速为0.2～2h-1；
3)活化后硅片，通过丝网印刷在银栅线上印刷多个均匀分布的导电胶组成Z字形，印刷压力为100～150N，速度为150～250mm/s；
4)继续通过印制机在硅片上印刷金属丝且使金属丝依次连接银栅线上的Z字形的导电胶。
有益效果：与现有技术相比，本发明具有以下优点：(1)实现了风光互补智能发电；(2)通过聚光凸面和外置聚光透镜提高光线接收能力进而提高天阳能电池的发电能力；(3)通过二次套印的丝网印刷技术，大大节约了银浆的使用量并降低了太阳能电池的成本；(4)优化银浆配方和生产制备工艺，提高了层间附着力和导电性能，从而降低接触电阻；(5)本发明的太阳能电池组件能快速便捷的在各种场合进行展开和折叠安装，结构牢固可靠，安装方便。
附图说明
图1为本发明所述太阳能电池组件的结构示意图；
图2为本发明所述电池片的结构示意图；
图3为图2中A-A方向的横截面示意图。
其中，电池片11、银栅线111、电极112、导电胶113、钢化白玻璃板12、EVA胶膜13、背板14、型材铝框15。
具体实施方式
下面结合附图和具体实施例，进一步阐明本发明，应理解这些实施例仅用于说明本发明而不用于限制本发明的范围，在阅读了本发明之后，本领域技术人员对本发明的各种等价形式的修改均落于本申请所附权利要求所限定的范围。
如图1～3所示，一种风光互补智能LED路灯，包括灯柱、设在灯柱上的LED灯头、风力发电机组、太阳能电池组件、设在灯柱内的蓄电池和控制器，所述风力发电机组包括设在灯柱顶端的风轮和设在灯柱内的发电机，所述太阳能电池组件设在灯柱上；所述风力发电机组的发电机与太阳能电池组件的输出端与蓄电池连接并同时与控制器数据连接，所述蓄电池对控制器和LED灯头供电；所述太阳能电池组件包括电池片、钢化白玻璃板、EVA胶膜、背板、接线盒、外置聚光透镜、和型材铝框，所述电池片包括硅片和设在硅片正面的银栅线和电极，所述电极为Z字形且与银栅线为垂直设置，通过引线将相邻电池片串并联后连接至接线盒，所述钢化白玻璃和背板分别设在电池片的上下方，且所述钢化玻璃与电池片之间以及背板与电池片之间设有EVA胶膜，所述型材铝框设在设在电池片四周；所述钢化白玻璃板的下表面设有与各电池片相对应的多个聚光凸面，所述外置聚光透镜设在电池片上方，且外置聚光透镜的尺寸为电池板的1.2～1.5倍。通过外置聚光透镜能聚集吸收更多太阳能，提高发电效率。
本发明中在灯柱顶端设置风力发电机组和太阳能电池组件，利用两者相互补充智能发电，最大化的节约用电。在太阳能电池组件中，相对于现有技术的2条或3条银浆烧结金属化主栅线，本发明采用Z字形的电极(相当于主栅)能更大化的收集光生电流，电池片进行串并联的引线焊接线只有一条，因此焊接点更少，提高了焊接效率；同时通过将上层的钢化玻璃制成多个聚光凸面可以更加聚集光线，提升太阳能硅电池的发电量。
作为优选，所述硅片正面的银栅线通过银浆丝网印刷后经过烧结金属化而成，所述电极为通过二次金属印制的金属丝，所述金属丝与银栅线的接触点之间印刷有导电胶。在主栅和副栅中，主要是副栅银浆在烧结过程中烧穿表层与P型硅基体形成欧姆接触，主栅主要起到收集光生电流的作用。因此，本发明在银浆烧结金属化的表面再二次套印金属丝形成主栅线，并在主栅线与金属化的副栅银线的接触点设置导电胶从而提高主栅线与副栅的结合力并降低两者之间的接触电阻，更重要的是节约了银浆的使用量，从而降低了成本。
作为优选，所述金属丝为铝丝或铜丝。铜丝具有更佳的导电能力，铝丝的抗抗氧化能更好。
作为优选，所述银浆有以下重量分数的组分构成：78～90份银粉、2～10份玻璃粉成型物质、2～6份磷酸铁锂、1～5份钛酸四乙酯附着力促进剂，2～3份松油醇、2～3份二甲酸二丁酯、1份磷酸三丁酯、0.1～1份的乙基纤维素、0.5～1.0份PVB30增稠剂和0.1～0.5份聚酰胺蜡防沉降剂。
本发明中银粉优选采用粒径为1.5～2.5微米的球状银粉，试验发现当银粉粒径小于1微米时，接触电阻会显著上升这是由于银粉颗粒过小表面势能大导致银粉颗粒溶解之前就已经烧结成块，只有较少银在表面重结晶使得重结晶银和硅表面表面的有效接触降低进而导致接触电阻增大。本发明中银浆的有机溶剂为松油醇、二甲酸二丁酯和磷酸三丁酯的三者复合溶剂，上述单一溶剂制成的载体或存放印刷时容易挥发使浆料粘度增大或载体不易挥发烘干后膜层交湿润，烧结后膜层边缘不起，层面容易出现较多的针孔缺陷。选用PVB30增稠剂提高了银浆塑型性能，并利用钛酸四乙酯提升银浆烧结后在硅基上的附着力，有利于形成欧姆接触。现有技术中依次丝网印刷中，银浆栅线的导电和附着力性能已足够，但由于本发明采用二次套印层间必然存在界面势能，因此采用聚酰胺蜡作为防沉降剂并与复合溶剂确保银粉颗粒的均匀分散和确保浆料的合适粘度。磷酸铁锂可以与银粉颗粒溶于硅基并在硅表面重结晶形成导电网格，提高导电性能降低太阳能电池的内电阻。
作为优选，所述玻璃粉成型物质为40～60％的TeO2、25～40％的P2O5、8～20％的ZnO和5～12％的Bi2O3，且各物质总和为100％的的混合物。传统的硅基玻璃粉在银浆中分散不够且会降低电极银浆在硅片上的附着力和导电能力，本发明采用碲磷铋锌的氧化物作为玻璃粉物质，
作为优选，还包括外置聚光透镜，所述外置聚光透镜设在电池板上方，且外置聚光透镜的尺寸为电池板的1.2～1.5倍。
本发明还提供了一种上述风光互补智能LED路灯的制备方法，包括以下步骤：
1)经过制绒、扩散、后清洗、镀膜和印刷背面电极后的硅片后，首先，在硅片正面表面上通过银浆丝网印刷多条银栅线，烘干后送入烧结炉中进行烧结金属化处理；
2)金属化处理后的硅片经过冷却送入活化箱，在携带二元酸气体的惰性气体作用下进行吹扫活化，温度控制在140～200℃，停留时间为10～45s，二元酸气体流速为0.2～2h-1；由于本发明采用二次套印技术，层间附着力和导电性能会受到影响，为了降低负面影响，本发明在一次丝网印刷金属化的硅片进行冷却到150～165℃时，送入活化箱通过惰性气体例如氮气携带高温气化的气相戊二酸，对银栅线表面进行活化形成有机酸的 羧基避免氧化，而且戊二酸与导电银胶有极佳的契合，改善导电胶在银栅线上的附着力并能活化导电胶中的银提高导电能力降低两者的接触电阻。
3)活化后硅片，通过丝网印刷在银栅线上印刷多个均匀分布的导电胶组成Z字形，印刷压力为100～150N，速度为150～250mm/s；
4)继续通过印制机在硅片上印刷金属丝且使金属丝依次连接银栅线上的Z字形的导电胶。
本发明还提供了一种风光互补智能LED路灯的太阳能电池组件，包括多个上述的太阳能硅电池板，以及安装支架、连接轴和柔性连接片材，所述多个太阳能硅电池板并排设置，且相邻两个太阳能硅电池板之间通过连接轴形成铰接，所述柔性连接片材铺设在太阳能硅电池板之间及太阳能硅电池板的四周形成整体，所述连接轴还设有滑轮；所述安装支架为框状结构，且设有与电池板上滑轮相匹配的滑轨，所述电池板连接轴上的滑轮设在滑轨上并能沿滑轨滑动使电池板展开或收起。
作为优选，所述柔性连接片材的四周设有安装孔；所述柔性连接片材为布料、皮革、人造革或柔性化纤片材；所述相邻电池组件的铝材边框上还设有缓冲垫。从而当将电池组件折叠时，缓冲垫能避免电池组件的玻璃表面发生接触甚至压碎。
Claims (6)
1.一种风光互补智能LED路灯，其特征在于：包括灯柱、设在灯柱上的LED灯头、风力发电机组、太阳能电池组件、设在灯柱内的蓄电池和控制器，所述风力发电机组包括设在灯柱顶端的风轮和设在灯柱内的发电机，所述太阳能电池组件设在灯柱上；所述风力发电机组的发电机与太阳能电池组件的输出端与蓄电池连接并同时与控制器数据连接，所述蓄电池对控制器和LED灯头供电；所述太阳能电池组件包括电池片、钢化白玻璃板、EVA胶膜、背板、接线盒、外置聚光透镜、和型材铝框，所述电池片包括硅片和设在硅片正面的银栅线和电极，所述电极为Z字形且与银栅线为垂直设置，通过引线将相邻电池片串并联后连接至接线盒，所述钢化白玻璃和背板分别设在电池片的上下方，且所述钢化玻璃与电池片之间以及背板与电池片之间设有EVA胶膜，所述型材铝框设在设在电池片四周；所述钢化白玻璃板的下表面设有与各电池片相对应的多个聚光凸面，所述外置聚光透镜设在电池片上方，且外置聚光透镜的尺寸为电池板的1.2～1.5倍。
2.根据权利要求1所述风光互补智能LED路灯，其特征在于：所述硅片正面的银栅线通过银浆丝网印刷后经过烧结金属化而成，所述电极为通过二次金属印制的金属丝，所述金属丝与银栅线的接触点之间印刷有导电胶。
3.根据权利要求1所述风光互补智能LED路灯，其特征在于：所述金属丝为铝丝或铜丝。
4.根据权利要求2所述风光互补智能LED路灯，其特征在于：所述银浆有以下重量分数的组分构成：78～90份银粉、2～10份玻璃粉成型物质、2～6份磷酸铁锂、1～5份钛酸四乙酯附着力促进剂，2～3份松油醇、2～3份二甲酸二丁酯、1份磷酸三丁酯、0.1～1份的乙基纤维素、0.5～1.0份PVB30增稠剂和0.1～0.5份聚酰胺蜡防沉降剂。
5.根据权利要求4所述风光互补智能LED路灯，其特征在于：所述玻璃粉成型物质为40～60％的TeO2、25～40％的P2O5、8～20％的ZnO和5～12％的Bi2O3，且各物质总和为100％的的混合物。
6.一种权利要求1～5任一所述风光互补智能LED路灯的制备方法，其特征在于所述电池片的制备方法包括以下步骤：
1)经过制绒、扩散、后清洗、镀膜和印刷背面电极后的硅片后，首先在硅片正面表面上通过银浆丝网印刷多条银栅线，烘干后送入烧结炉中进行烧结金属化处理；
2)金属化处理后的硅片经过冷却送入活化箱，在携带二元酸气体的惰性气体作用下进行吹扫活化，温度控制在140～200℃，停留时间为10～45s，二元酸气体流速为0.2～2h-1；
3)活化后硅片，通过丝网印刷在银栅线上印刷多个均匀分布的导电胶组成Z字形，印刷压力为100～150N，速度为150～250mm/s；
4)继续通过印制机在硅片上印刷金属丝且使金属丝依次连接银栅线上的Z字形的导电胶。
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Application publication date: 20161214 |