CN107475658A - 太阳能电池板加工装置电弧复合涂层加工方法 - Google Patents
太阳能电池板加工装置电弧复合涂层加工方法 Download PDFInfo
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Abstract
本发明公开一种太阳能电池板加工装置电弧复合涂层加工方法,其采用两次溶射生成复合涂层,第一层采用不锈钢材质,第二层采用纯铝材质生成,可与不锈钢基体有力结合。采用本发明工艺生成的复合涂层不仅厚度与粗糙度可达到CIGS加工要求,而且,涂层与基材结合力好,产品使用寿命长。
Description
技术领域
本发明公开一种复合涂层加工方法,特别是一种太阳能电池板加工装置电弧复合涂层加工方法。
背景技术
CIGS,即薄膜太阳能电池,主要由Cu(铜)、In(铟)、Ga(镓)、Se(硒)四种元素构成最佳比例的黄铜矿结晶薄膜太阳能电池,是组成太阳能电池板的关键技术。由于该产品具有光吸收能力强,发电稳定性好、转化效率高,白天发电时间长、发电量高、生产成本低以及能源回收周期短等诸多优势,CIGS太阳能电池已是太阳能电池产品的明日之星,可以与传统的晶硅太阳能电池相抗衡。薄膜太阳能电池在生产过程中,其用到的加工装置中有一种为不锈钢材质制成,为了达到某些特殊性能,且延长该加工装置的使用寿命,薄膜太阳能电池加工装置外部需要设置特殊涂层才能满足要求,而目前普通工艺制成的涂层容易脱落,不能满足CIGS加工装置的要求。
发明内容
针对上述提到的现有技术中的CIGS加工装置的外侧涂层结合力低的缺点,本发明提供一种新的太阳能电池板加工装置电弧复合涂层加工方法,其采用二次溶射工艺在CIGS加工装置外侧形成一层复合涂层,其与基体结合力好。
本发明解决其技术问题采用的技术方案是:一种太阳能电池板加工装置电弧复合涂层加工方法,该加工方法包括下述步骤:
S1、剥离原溶射层:采用超高压水洗机利用超高压纯水进行喷射剥离;
S2、工件纯水漂洗:将步骤S1处理后的工件捞出,放入流动的纯水中浸泡冲洗30分钟以上,以去除工件表面残余的颗粒物;
S3:超声波清洗:将步骤S2处理后的工件放入超声波清洗槽中,超声波清洗槽中放入纯水,采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上,以去除工件表面的残存的颗粒物质;
S4、干燥:采用CDA吹干;
S5、喷砂:采用喷砂工艺对工件进行表面喷砂处理,保证不锈钢材质工件表面粗糙度达到Ra:5-8μm;
S6、高压水洗:采用高压纯水对工件表面进行水洗;
S7、超声波清洗:将步骤S6清洗后的工件放入超声波清洗槽中,超声波清洗槽中放入纯水,采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上;
S8、干燥:采用CDA吹干,干燥温度为100±5℃,干燥时间为30分钟以上;
S9、对工件表面进行溶射作业:溶射作业采用两次溶射形成表面复合涂层:
复合涂层一工艺:涂层一中的溶射材质采用不锈钢,不锈钢成份的重量百分比为:碳(C):≤0.03%,硅(Si):0.3%~0.65%,锰(Mn):1%~2.5%,磷(P):≤0.03%,硫(S):≤0.02%,铬(Cr):18%~20%,镍(Ni):11%~14%,铜(Cu):≤0.75%,钼(Mo):2.0%~3.0%,其余为铁,溶射时焰心温度为6000±100℃,直径1.6mm的不锈钢线材,喷射气压为50±5psi,溶射间距为200-300mm,溶射角度为45-90度,溶射速度为400±50mm/s;
复合涂层二工艺:涂层二中的溶射材质采用纯铝,溶射时焰心温度为6000±100℃,溶射材质采用纯度为99.9%,直径1.6mm的铝线,喷射气压为20±2psi,溶射间距为200-300mm,溶射角度为45-90度,溶射速度为350±30mm/s;
S10、采用粗糙度检测仪对溶射后的工件表面进行粗糙度检测,保证工件表面粗糙度达到Ra:2500±15%μinch,采用千分尺对溶射层后进行检测,溶射层的厚度为0.04±0.004inch;
S11、高压水洗:采用高压纯水对工件表面进行水洗,高压水枪的水压保持在50bar以上,水枪出水口距工件表面的距离为30~50cm,对工件表面进行全面高压水清洗;
S12、超声波清洗:将步骤S11中的工件放入超声波清洗槽中,超声波清洗槽中放入纯水,采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上;
S13、干燥:采用CDA吹干,干燥温度为150±5°,干燥时间为6小时以上;
S14、最终检验:采用表面粒子测定仪对工件进行表面检测,颗粒尺寸为0.3μm以上的颗粒每平方厘米少于3个,如果不合格则返回至步骤S12,再次进行超声波水洗,如果合格即完成。
本发明解决其技术问题采用的技术方案进一步还包括:
所述的步骤S1中超高压水洗机的喷射压力超过200MPa,采用电阻率:>5MΩ.cm的去离子纯水。
所述的步骤S4中干燥温度为100±5℃,干燥时间为30分钟以上。
所述的步骤S5中采用WA20#,利用压力为3~5Kgf/cm2的喷砂工艺,喷砂机的喷嘴出口距工件表面的距离为300±50mm的距离,喷砂机的喷射角度为45°~90°的角度。
所述的S6中高压水枪的水压保持在50bar以上,水枪出水口距工件表面的距离为30~50cm。
所述的涂层一中的不锈钢成份百分比为:碳(C):0.0285%,硅(Si):0.58%,锰(Mn):1.71%,磷(P):0.028%,硫(S):0.009%,铬(Cr):18.24%,镍(Ni):11.17%,铜(Cu):0.34%,钼(Mo):2.11%,其余为铁。
所述的步骤S9中涂层一熔射后的厚度可达为0.02±0.002inch,复合涂层一的粗糙度为Ra:1400±15%μinch。
所述的步骤S9中涂层二熔射后的厚度可达到0.02±0.002inch,复合涂层二的粗糙度为Ra:2500±15%μinch。
本发明的有益效果是:采用本发明工艺生成的复合涂层不仅厚度与粗糙度可达到CIGS加工要求,而且,涂层与基材结合力好,产品使用寿命长。
具体实施方式
本实施例为本发明优选实施方式,其他凡其原理和基本结构与本实施例相同或近似的,均在本发明保护范围之内。
本发明主要为一种CIGS加工装置电弧复合涂层加工方法,其采用99.9%纯铝和不锈钢作为溶射涂层的材料,在CIGS加工装置(CIGS加工装置本体主要由不锈钢材质制成)外表面上面溶射形成两层涂层,本发明的溶射加工方法主要包括下述步骤:
S1、剥离原溶射层:本实施例中,采用超高压水洗机利用超高压纯水进行喷射剥离,本实施例中,超高压水洗机的喷射压力超过200MPa,采用纯水为DIW(Deionized water,去离子水),电阻率:>5MΩ·cm,由于基体为不锈钢材质制成,第一溶射层为不锈钢,第二溶射层为纯铝,采用超高压水洗机很容易将元溶射层剥离,而不损坏本体;
S2、工件纯水漂洗:将步骤S1处理后的工件捞出,放入流动的纯水(电阻率为12MΩ·cm以上的纯水)中浸泡冲洗30分钟以上,以去除工件表面残余的颗粒物;
S3:超声波清洗:将步骤S2处理后的工件放入超声波清洗槽中,超声波清洗槽中放入纯水(电阻率为12MΩ·cm以上的纯水),采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上,以去除工件表面的残存的颗粒物质;
S4、干燥:采用CDA(去油去水压缩空气)吹干,干燥温度为100±5℃,干燥时间为30分钟以上,除了可去除表面残留水分外,还可去除基体内部渗入的水分;
S5、喷砂:采用WA20#(即20#的白刚玉,颗粒尺寸为800~630μm),利用压力为3~5Kgf/cm2的喷砂工艺,喷砂机的喷嘴出口距工件表面的距离为300±50mm的距离,喷砂机的喷射角度为45°~90°的角度,对工件进行表面喷砂处理,以增加工件表现粗糙度,喷砂过程中利用粗糙度检测仪对工件表面进行粗糙度检测,保证不锈钢(即SUS)材质工件表面粗糙度达到Ra:5-8μm;
S6、高压水洗:采用高压纯水(电阻率为12MΩ·cm以上的纯水)对工件表面进行水洗,清洗时,高压水枪的水压保持在50bar以上,水枪出水口距工件表面的距离为30~50cm,对工件表面进行全面高压水清洗;
S7、超声波清洗:将步骤S6清洗后的工件放入超声波清洗槽中,超声波清洗槽中放入纯水(电阻率为12MΩ·cm以上的纯水),采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上,以去除工件表面的残存的颗粒物质;
S8、干燥:采用CDA(去油去水压缩空气)吹干,干燥温度为100±5℃,干燥时间为30分钟以上,以达到去除工件上的水分的目的;
S9、对工件表面进行溶射作业:本实施例中,溶射作业采用两次溶射形成表面复合涂层:
复合涂层一工艺:本涂层中的溶射材质采用不锈钢,不锈钢成份(以重量百分比计算)为:碳(C):≤0.03%,硅(Si):0.3%~0.65%,锰(Mn):1%~2.5%,磷(P):≤0.03%,硫(S):≤0.02%,铬(Cr):18%~20%,镍(Ni):11%~14%,铜(Cu):≤0.75%,钼(Mo):2.0%~3.0%,其余为铁。优选的不锈钢成份(以重量百分比计算)为:碳(C):0.0285%,硅(Si):0.58%,锰(Mn):1.71%,磷(P):0.028%,硫(S):0.009%,铬(Cr):18.24%,镍(Ni):11.17%,铜(Cu):0.34%,钼(Mo):2.11%,其余为铁。溶射时焰心温度为6000±100℃,直径1.6mm的不锈钢线材,喷射气压为50±5psi,溶射间距(溶射喷枪出口至工件表面的距离)为200-300mm,溶射角度(速溶射喷枪出口中心线与工件表面之间的夹角)为45-90度,溶射速度(速溶射喷枪的移动速度)为400±50mm/s,熔射后本层复合涂层的厚度可达到0.02±0.002inch,层复合涂层的粗糙度为Ra:1400±15%μinch,本实施例中,第一复合层熔射一遍,该层涂层形成高致密度涂层,与基体结合力强;
本实施例中,溶射作业采用Praxair Surface Technologies,Inc.(即美国普莱克斯表面技术公司)生产的型号为Model 9935Gun的溶射喷枪,该喷枪的参数设计为:电流:150A,电压:30V,气压:50psi,溶射间距:200-300mm,溶射角度:45-90度,溶射速度:400mm/s。
复合涂层二工艺:本涂层中的溶射材质采用纯铝(纯度为99.9%的铝),溶射时焰心温度为6000±100℃,溶射材质采用纯度为99.9%,直径1.6mm的铝线,喷射气压为20±2psi,溶射间距(溶射喷枪出口至工件表面的距离)为200-300mm,溶射角度(速溶射喷枪出口中心线与工件表面之间的夹角)为45-90度,溶射速度(速溶射喷枪的移动速度)为350±30mm/s,熔射后本层复合涂层的厚度可达到0.02±0.002inch,第二层复合涂层的粗糙度为Ra:2500±15%μinch,本实施例中,第二复合层也是熔射一遍,该层涂层与第一复合层紧密结合在一起,达到结合力最强;
本实施例中,该层溶射作业也是采用Praxair Surface Technologies,Inc.(即美国普莱克斯表面技术公司)生产的型号为Model 9935Gun的溶射喷枪,该喷枪的参数设计为:电流:170A,电压:28V,气压:20psi,溶射间距:200-300mm,溶射角度:45-90度,溶射速度:250mm/s。
经两层喷涂,达到设定厚度和粗糙度,整体厚度为0.04±0.004inch;
S10、粗糙度采用粗糙度检测仪对溶射后的工件表面进行粗糙度检测,保证工件表面粗糙度达到Ra:2500±15%μinch,溶射层的厚度为0.04±0.004inch,本实施例中,溶射层的厚度采用千分尺检测,即熔射喷涂前用千分尺测量一侧,溶射喷涂后再测量一次,两次的差即为溶射层厚度,如果检测不合格,则返回步骤S1,重新进行剥离、清洗、溶射;如果检测合格则进入下一步骤;
S11、高压水洗:采用高压纯水(电阻率为12MΩ·cm以上的纯水)对工件表面进行水洗,清洗时,高压水枪的水压保持在50bar以上,水枪出水口距工件表面的距离为30~50cm,对工件表面进行全面高压水清洗;
S12、超声波清洗:将步骤S11中的工件放入超声波清洗槽中,超声波清洗槽中放入纯水,采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上,以去除工件表面的残存的颗粒物质;
S13、干燥:采用CDA(去油去水压缩空气)吹干,干燥温度为150±5°,干燥时间为6小时以上;
S14、最终检验:采用表面粒子测定仪对工件进行表面检测,其中,颗粒尺寸为0.3μm以上的颗粒每平方厘米少于3个,如果不合格则返回至步骤S12,再次进行超声波水洗,如果合格即完成。
采用本发明工艺生成的复合涂层不仅厚度与粗糙度可达到CIGS加工要求,而且,涂层与基材结合力好,产品使用寿命长。
Claims (8)
1.一种太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的加工方法包括下述步骤:
S1、剥离原溶射层:采用超高压水洗机利用超高压纯水进行喷射剥离;
S2、工件纯水漂洗:将步骤S1处理后的工件捞出,放入流动的纯水中浸泡冲洗30分钟以上,以去除工件表面残余的颗粒物;
S3:超声波清洗:将步骤S2处理后的工件放入超声波清洗槽中,超声波清洗槽中放入纯水,采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上,以去除工件表面的残存的颗粒物质;
S4、干燥:采用CDA吹干;
S5、喷砂:采用喷砂工艺对工件进行表面喷砂处理,保证不锈钢材质工件表面粗糙度达到Ra:5-8μm;
S6、高压水洗:采用高压纯水对工件表面进行水洗;
S7、超声波清洗:将步骤S6清洗后的工件放入超声波清洗槽中,超声波清洗槽中放入纯水,采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上;
S8、干燥:采用CDA吹干,干燥温度为100±5℃,干燥时间为30分钟以上;
S9、对工件表面进行溶射作业:溶射作业采用两次溶射形成表面复合涂层:
复合涂层一工艺:涂层一中的溶射材质采用不锈钢,不锈钢成份的重量百分比为:碳(C):≤0.03%,硅(Si):0.3%~0.65%,锰(Mn):1%~2.5%,磷(P):≤0.03%,硫(S):≤0.02%,铬(Cr):18%~20%,镍(Ni):11%~14%,铜(Cu):≤0.75%,钼(Mo):2.0%~3.0%,其余为铁,溶射时焰心温度为6000±100℃,直径1.6mm的不锈钢线材,喷射气压为50±5psi,溶射间距为200-300mm,溶射角度为45-90度,溶射速度为400±50mm/s;
复合涂层二工艺:涂层二中的溶射材质采用纯铝,溶射时焰心温度为6000±100℃,溶射材质采用纯度为99.9%,直径1.6mm的铝线,喷射气压为20±2psi,溶射间距为200-300mm,溶射角度为45-90度,溶射速度为350±30mm/s;
S10、采用粗糙度检测仪对溶射后的工件表面进行粗糙度检测,保证工件表面粗糙度达到Ra:2500±15%μinch,采用千分尺对溶射层后进行检测,溶射层的厚度为0.04±0.004inch;
S11、高压水洗:采用高压纯水对工件表面进行水洗,高压水枪的水压保持在50bar以上,水枪出水口距工件表面的距离为30~50cm,对工件表面进行全面高压水清洗;
S12、超声波清洗:将步骤S11中的工件放入超声波清洗槽中,超声波清洗槽中放入纯水,采用有效功率为1.2Kw的超声波进行超声波震荡清洗30分钟以上;
S13、干燥:采用CDA吹干,干燥温度为150±5°,干燥时间为6小时以上;
S14、最终检验:采用表面粒子测定仪对工件进行表面检测,颗粒尺寸为0.3μm以上的颗粒每平方厘米少于3个,如果不合格则返回至步骤S12,再次进行超声波水洗,如果合格即完成。
2.根据权利要求1所述的太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的步骤S1中超高压水洗机的喷射压力超过200MPa,采用电阻率:>5MΩ.cm的去离子纯水。
3.根据权利要求1所述的太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的步骤S4中干燥温度为100±5℃,干燥时间为30分钟以上。
4.根据权利要求1所述的太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的步骤S5中采用WA20#,利用压力为3~5Kgf/cm2的喷砂工艺,喷砂机的喷嘴出口距工件表面的距离为300±50mm的距离,喷砂机的喷射角度为45°~90°的角度。
5.根据权利要求1所述的太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的S6中高压水枪的水压保持在50bar以上,水枪出水口距工件表面的距离为30~50cm。
6.根据权利要求1所述的太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的涂层一中的不锈钢成份百分比为:碳(C):0.0285%,硅(Si):0.58%,锰(Mn):1.71%,磷(P):0.028%,硫(S):0.009%,铬(Cr):18.24%,镍(Ni):11.17%,铜(Cu):0.34%,钼(Mo):2.11%,其余为铁。
7.根据权利要求1所述的太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的步骤S9中涂层一熔射后的厚度可达为0.02±0.002inch,复合涂层一的粗糙度为Ra:1400±15%μinch。
8.根据权利要求1所述的太阳能电池板加工装置电弧复合涂层加工方法,其特征是:所述的步骤S9中涂层二熔射后的厚度可达到0.02±0.002inch,复合涂层二的粗糙度为Ra:2500±15%μinch。
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