FR3081768A1 - METHOD FOR ASSEMBLING DIFFERENT THICKNESS MODULES FOR THEIR INTEGRATION IN A GLASS PRODUCT - Google Patents

Abstract

The invention relates to a method for manufacturing a new glass product, and the glass product obtained. The glass product consists of a stack comprising two upper (1B) and lower (1A) barrier surfaces, at least two modules (2A, 2B) of respective thicknesses (E1, E2) different such as E1> E2, joined to form a set of contiguous modules having an upper face and a lower face, an upper interlayer (4S) disposed between the upper barrier surface (1B) and the modules (2A, 2B), a lower interlayer (4I) disposed between the lower barrier surface (1A) and the modules (2A, 2B), one or more seals (5A, 5B) arranged on the periphery of the product, characterized in that it also comprises one or more intermediate spacers (4) arranged astride on the modules (2A, 2B) and having a thickness such that the thickness of the intermediate interlayer portion (4) located opposite the thickest module (2A) is less by a value (E1 - E2) than the thickness of the portion of intermediate interlayer (4) located opposite the thinner module (2B), so as to compensate for the differences in thickness between two modules (2A, 2B).

Description

The present invention relates to a method of assembling modules of different thicknesses for integration into a glass product.

STATE OF THE ART

Photovoltaic energy production devices for self-consumption and / or self-production are very popular in the building industry today. The BIPV industry (acronym for “Building Integrated Photovoltaics”) is currently investigating new architectural solutions, in particular through the integration of photovoltaic devices in glass products.

The assemblies of traditional glass products are governed by lamination techniques well known in the glass industry, commonly called lamination, and used in particular for the manufacture of safety glass. The glasses to be assembled are bonded, during the lamination process, by a thermoplastic or thermosetting film such as PVB (English acronym for "Polyvinyl Butyral") or EVA (English acronym for "Ethylene Vinyl Acetate"). Document EP0331648-A2 describes a process for manufacturing two glasses laminated with an adhesive layer of PVB, the whole being arranged in a flexible support in which the vacuum can be created, the assembly being heated to a temperature between 130 and 150 ° C at constant pressure. The patents US5536347 and W02009039053-A1 describe processes for manufacturing laminated glass without an autoclave. These techniques make it possible to reduce the costs of manufacturing glass products.

Similarly, the photovoltaic industry uses lamination processes allowing the encapsulation of the materials composing the cells in order to protect them from environmental aggressions (chemical and mechanical). These materials can be inorganic or organic, crystalline or amorphous materials. They can be in thin layers, for example based on amorphous silicon (a-Si) or an alloy of copper, indium, galium and selenium (CIGS). Thin film photovoltaic devices are made up of a stack of several layers of materials, with thicknesses that can range from a few nanometers to a few micrometers, depending on the architecture.

When the transparency of photovoltaic devices is sought, materials in thin layers are particularly suitable, because of their small thickness, for the methods of manufacturing the semi-transparent module, as described for example in patent JP2012074619-A. In order to protect said materials from environmental attack, they are encapsulated by a barrier surface, generally formed by a protective glass. They are linked by a very transparent encapsulation film, the refractive index of which is close to that of glass to limit optical losses at interfaces, such as EVA or PVB, and by a seal, for example in Poly Isobutylene (PIB). The encapsulation process can then be carried out by hot pressing under vacuum. A double-glass laminate is thus obtained as described for example in patent US4625070, or more complex devices comprising a plurality of glass substrates arranged on either side of the photovoltaic material as described in patent WO2012103190-A1.

In addition, the photovoltaic industry today offers two-glass modules of different dimensions and power, however currently the maximum size of a photovoltaic module in thin inorganic layers deposited on rigid substrates is limited, and does not exceed 1 , 10m x 1.40m.

The BIPV market demands that photovoltaic devices conform to the building industry, in particular through their dimensions, in order to facilitate their integration into joinery and into various architectural projects. In order to meet these requirements, it is necessary to develop large glass products, that is to say areas greater than 2 m ² . The assembly of several photovoltaic modules and / or photovoltaic modules combined with other products (glassmakers or not), and which do not necessarily have equivalent thicknesses, is crucial. The problems of laminating such assemblies, having one or more modules of different thicknesses encapsulated between two protective glasses, are numerous. For example, if the height between the devices to be assembled is not equivalent, air bubbles visible to the naked eye may appear at the join of the devices during the lamination process. The lamination process can also cause all or part of said modules to break.

The invention aims to solve these technical assembly problems while maximizing the functionality and aesthetics of the assembled product.

PURPOSE OF THE INVENTION

The subject of the invention is a method of assembling contiguous modules of different thicknesses with a view to their hot lamination under vacuum so that they are integrated into a large glass product. Said method makes it possible to avoid the breakage of said modules and minimizes the appearance of bubbles during the lamination of said glass product.

OBJECTS OF THE INVENTION

In its basic principle, the invention relates to a process for assembling contiguous modules of different thicknesses with a view to their hot lamination under vacuum so that they are integrated into a large glass product.

In the rest of the document, a distinction is made between crosslinked encapsulation films (or interleaves) and non-crosslinked encapsulation films. The crosslinked encapsulation films result from the hot lamination under vacuum of the noncrosslinked encapsulation films. One or more encapsulation films of the same dimensions and superimposed on each other within said assembly are called interlayer.

The invention therefore has as a first object a method of assembling a glass product with a view to its lamination, comprising the following steps:

A) Supply at least:

- two upper and lower barrier surfaces;

- one or more seals;

- an upper interlayer;

- a lower spacer;

- one or more intermediate dividers;

- At least two modules of different thicknesses (El, E2) such as E1> E2, joined to form a set of contiguous modules having an upper face and a lower face;

B) then form an assembly such as:

- Said upper barrier surface is in contact with one or more seals and said upper interlayer;

- Said lower barrier surface is in contact with one or more seals and said lower interlayer;

- All of said modules has an overall surface less than or equal to the smallest of the barrier surfaces;

- The lower faces of said modules are in contact with the lower interlayer;

the method being characterized in that:

the upper face of the thinner module is completely covered, close to the surface of the joints, by an intermediate interlayer, and the upper face of the thicker module is partly covered by one or more intermediate interlayer and partly by the 'upper tab.

Advantageously, the thicknesses of the upper (respectively lower) spacers are chosen as a function of the physicochemical nature of the upper (respectively lower) barrier surfaces.

Advantageously, the shapes and dimensions of the upper and lower spacers are chosen as a function of the shapes and dimensions of all the adjoining modules, apart from the seals.

According to one embodiment, the intermediate interlayer (s) placed astride the modules are chosen to have a thickness such that the thickness of the intermediate interlayer portion located opposite the thickest module is less by an equal value or approximately equal to (E1 - E2) the thickness of the intermediate interlayer portion situated opposite the thinner module, so as to compensate for the differences in thickness between two modules.

According to one embodiment, so that the intermediate interlayer can perform its thickness compensation function, its thickness E is preferably chosen such that 0.8 * (E1-E2) <E <1.2 * (E1- E2) so as to compensate for the difference between the thicknesses E1, E2 of the two adjoining modules.

According to one embodiment, the spacers are composed of EVA encapsulation films.

Preferably, the upper and lower barrier surfaces have the same shapes and the same dimensions.

According to an advantageous embodiment, one of the modules is a photovoltaic module.

According to one embodiment, the module (s) adjoining the photovoltaic module is (are) a module (s) made of glass, plastic, rigid (s), semi-rigid (s) or flexible.

Advantageously, the module (s) adjoining the photovoltaic module is (are) a functional module (s), such as an electrochromic module.

According to one embodiment, the barrier surfaces are toughened glasses.

According to an alternative embodiment, the barrier surfaces are float glasses.

The invention also relates to a glass product characterized in that it is obtained using the assembly process according to the invention.

According to an advantageous embodiment, the glass product is constituted by a stack comprising two upper and lower barrier surfaces, at least two modules of respective thicknesses (El, E2) different such as E1> E2, joined to form a set of modules joints having an upper face and a lower face, an upper interlayer arranged between the upper barrier surface and the modules, a lower interlayer arranged between the lower barrier surface and the modules, one or more seals arranged on the periphery of the product, characterized in that it further comprises one or more intermediate spacers disposed astride the modules and having a thickness such that the thickness of the intermediate spacer portion located opposite the thickest module is less by an equal value or close to (El - E2), to the thickness of the intermediate interlayer portion re located next to the thinnest module, so as to compensate for the differences in thickness between two modules.

According to an advantageous use of the glass product according to the invention, the photovoltaic module is configured to play the role of receiver in a wireless optical communication system.

DETAILED DESCRIPTION

The invention is now described in more detail using the description of Figures IA to 4.

Figures IA to 1D are diagrams in top view of products resulting from an intermediate stage of the assembly process according to the invention, consisting of joining two modules of different thicknesses so that they are joined.

Figure 2 is a diagram showing a sectional view of a glass product according to the state of the art, including two photovoltaic modules of the same thickness.

FIG. 3A represents a sectional view of a first glass product according to the invention, including a photovoltaic module assembled with a transparent module of different thickness.

FIG. 3B represents a sectional view of part of the product resulting from the method of assembling said first glass product according to the invention.

Figure 4 shows a sectional view of part of the product from the assembly process of a second glass product according to the invention not shown.

Figures IA to 1D are diagrams in top view of products resulting from an intermediate stage of the assembly method according to the invention, which consists in placing at least two contiguous modules of different thicknesses side by side. In particular, FIG. IA is a simple case for which two modules (2A, 2B) of rectangular shapes are joined according to their width so that they are contiguous. FIG. 1B is another example where four modules (2A, 2C, 2D, 2E) of the same triangular shapes and of the same thickness are associated with a module 2B of diamond shape and of different thickness. They are joined two by two according to one of their side. For these first two examples, the geometric shapes are polygonal, but the invention is not limited to this type of shape. In particular, two modules of curved shapes can be joined as soon as their shapes are complementary. FIG. 1C is an example in which a first module 2B of the half-disc type is nested with a second module 2A of complementary shape and of different thickness. FIG. 1D comprises a first module 2A of ovoid shape combined on either side with two other modules (2A, 2C) of complementary shapes and thicknesses different from that of the first module 2A. The thicknesses of modules 2A and 2C may or may not be the same.

Figure 2 is a diagram showing a sectional view of a photovoltaic glass product according to the state of the art. This glass product has the particularity of including the assembly of two photovoltaic modules (2A, 2B) juxtaposed laterally. In this example, the two photovoltaic modules (2A, 2B) have the same physical characteristics, in particular, they have the same thickness El. The photovoltaic glass product is composed:

- a lower barrier surface (IA), for example a tempered glass;

- an upper barrier surface (IB), for example a second tempered glass;

- a first photovoltaic module (2A) comprising an active upper face (2AA) and a non-active lower face (2ANA);

- a first collection bus (3A-) corresponding to the negative terminal of the second photovoltaic module;

- a second photovoltaic module (2B) comprising an active upper face (2BA) and a non-active lower face (2BNA);

- a second electric current collection bus (3B-) corresponding to the negative terminal of the second photovoltaic module;

- a central collection bus (3C +) corresponding to the positive terminals of all of the two photovoltaic modules (2A, 2B);

- a first crosslinked spacer (4A) disposed between the non-active lower faces of the photovoltaic modules (2A, 2B) and the lower barrier surface (IA);

- seals (5A) ensuring sealing between the lower barrier surface (IA) and the lower faces (2ANA, 2BNA) of the photovoltaic modules (2A, 2B);

- a second crosslinked interlayer (4B) disposed between the upper faces of the photovoltaic modules (2A, 2B) and the upper barrier surface (IB);

-seals (5B) ensuring the seal between the upper barrier surface (IB) and the active upper faces (2AA, 2BA) of the photovoltaic modules (2A, 2B).

In this example, according to the state of the art, the lower and upper barrier surfaces (IA, IB) have the same shapes and dimensions, that is to say the same widths and lengths. Their thicknesses can however be different.

The collection buses (3A-, 3B-) collect the electrons from the photovoltaic modules (2A, 2B). The central collection bus (3C +) overlaps each of the two photovoltaic modules (2A, 2B), which allows the electrical junction of said photovoltaic modules (2A, 2B).

In this example, the two photovoltaic modules (2A, 2B) adhere on the side of their non-active lower faces (2ANA, 2BNA) to the lower barrier surface (IA) thanks to a first crosslinked interlayer (4A). They adhere on the side of their active upper faces (2AA, 2BA) to the upper barrier surface (IB) thanks to a second crosslinked interlayer (4B) having the other function of encapsulating the photovoltaic modules (2A, 2B). The two crosslinked spacers (4A, 4B) can be of the same physico-chemical nature or of different natures. These are, for example, EVA type polymers (acronym of ethylene-vinyl acetate), polyolefins or else polyurethanes. Their thicknesses (E4A and E4B respectively) are adapted to the thickness of the barrier surfaces (E1A and E1B respectively). For example, for a tempered glass barrier surface with a thickness E1A of 12 mm, an EVA interlayer with a thickness E4A of 1.6 mm could be used.

The seals (5A, 5B) are placed on the periphery of the barrier surfaces (IA, IB). Their function is to guarantee the tightness of the entire glass product, and in particular to protect the photovoltaic modules (2A, 2B) from physical and chemical attack from the external environment. Preferably, their exterior and interior lengths (respectively widths) are adapted to the lengths (respectively widths) of the barrier surfaces and of the photovoltaic modules. They can for example consist of GDP.

In this type of assembly of glass product including two photovoltaic modules of the same thickness, the lamination methods known to those skilled in the art allow assembly without the appearance of air bubbles at the glass / crosslinked interlayer interfaces, or breakage of material. However, such problems arise when the two modules to be assembled have different thicknesses, for example, when a photovoltaic module must be combined with bare glass.

FIG. 3A is a diagram representing a sectional view of a first glass product according to the invention, including a photovoltaic module (2A) assembled with a transparent module (2B) of different thickness. This sectional view is that of a glass product directly derived from the intermediate product shown in FIG. IA, along the axis X. Said first photovoltaic glass product is composed:

- a lower barrier surface (IA), the internal face of which is denoted lAi;

- an upper barrier surface (IB), the internal face of which is denoted IBi;

- a photovoltaic module (2A) of thickness El, comprising an active upper face (2AA) and a non-active lower face (2ANA);

- a transparent module (2B), of thickness E2 <El and comprising an upper face (2Bs) and a lower face (2Bi);

- two collection buses (3A-, 3A +);

- a first crosslinked interlayer (4A) disposed between the lower faces (2ANA, 2Bi) of the contiguous modules (2A, 2B) and the lower barrier surface (IA);

- seals (5A) ensuring the seal between the lower barrier surface (IA) and the lower faces (2ANA, 2Bi) of the contiguous modules (2A, 2B);

- a second crosslinked interlayer (4B) disposed between the upper faces (2AA, 2Bs) of the contiguous modules (2A, 2B) and the upper barrier surface (IB);

- seals (5B) ensuring the seal between the upper barrier surface (IB) and the upper faces (2AA, 2Bs) of the jointing modules (2A and 2B).

FIG. 3B represents a sectional view of part of the product resulting from the method of assembling said first glass product according to the invention. The collection buses and the barrier surfaces are not shown.

During the assembly process according to the invention, the non-crosslinked interlayer (which will form after lamination the crosslinked interlayer 4B of the first glass product) is composed of an upper interlayer 4S and an intermediate interlayer (4). In order to avoid the appearance of air bubbles and / or breakage of materials during lamination, the intermediate interlayer (4) is an overflow interlayer. This means that it completely covers (with the seals (5B) close) the module (2B) of thinner thickness E2 and partially the photovoltaic module (2A) on the side of its active face (2AA). As for the upper interlayer (4S), which is arranged on the intermediate interlayer (4), it perfectly covers the two adjoining modules (2A, 2B) apart from the seals (5B). The lower interlayer (41), which is arranged under the two adjoining modules (2A, 2B), has the same dimensions as the assembly formed by the two adjoining modules (2A, 2B) except for the seals (5A) .

Advantageously, the upper (4S) and intermediate (4) spacers have the same physico-chemical nature. During the lamination process, they crosslink perfectly and make it possible to compensate for the difference in thickness (E1-E2) between the photovoltaic module (2A) and the transparent module (2B). One of the advantages of using the same interlayer material is to homogenize the visual impact which two interleavers of different physicochemical natures would have brought, in particular by optical phenomena at their interface.

Furthermore, it is known to those skilled in the art that the recommended thickness of the spacers depends on the nature of the material constituting the barrier surface. For example, the table below gives recommendations concerning the number of EVA encapsulation films forming the different upper and lower tabs, depending on whether the barrier surface is made of tempered or float glass.

Barrier nature Barrier thickness Number and thickness of EVA films recommended to form the dividers FLEET GLASS 3 mm to 6 mm 2 films in 0.38 mm (or 0.4 mm) HEAT-TEMPERED GLASS 3 mm to 6 mm 2 or 3 films in 0.38 mm (or 0.4 mm) FLEET GLASS 8 mm and 10 mm 3 films in 0.38 mm (or 0.4 mm) HEAT-TEMPERED GLASS 8 mm and 10 mm 3 or 4 films in 0.38 mm (or 0.4 mm) FLEET GLASS 12 mm 3 to 4 films in 0.38 mm (or 0.4 mm) HEAT-TEMPERED GLASS 12 mm 4 films in 0.38 mm (or 0.4 mm) FLEET GLASS 15 mm 4 films in 0.38 mm (or 0.4 mm) HEAT-TEMPERED GLASS 15 mm 4 or 5 films in 0.38 mm (or 0.4 mm)

This type of assembly with multiple spacers can be applied to any type of arrangement having differences in thickness between the different parts to be assembled. For example, for aesthetic reasons, it may be advantageous to have a transparent module (2B) of thickness E2 less than El at the center of four photovoltaic modules (2A, 2C, 2D, 2E) of thickness El, as shown in Figure IB.

4 shows a sectional view of part of the product shown in Figure IB, along the axis T, for the assembly of a second glass product according to the invention. The intermediate interlayer (4) has an overflow on the modules (2A, 2E). The upper (4S) and lower (41) spacers have the same shape and same dimension 5 as all of the adjoining modules (2A, 2B, 2C, 2D, 2E), except for the seals (5B, 5A).

Those skilled in the art will know how to make the electrical interconnections between the various collection buses of the various photovoltaic modules. These interconnections are therefore not recalled here and do not form part of the object of the invention.

IA Lower barrier surface Lai Internal surface of the lower barrier surface IB Upper barrier surface IBi Internal surface of the upper barrier surface 2A, 2B, 2C, 2D Module 2Bi Lower surface of module 2B 2bs Upper surface of module 2B 2AA, 2BA Active upper face of a photovoltaic module 2ANA, 2BNA Non-active underside of a photovoltaic module 3A-, 3B-, 3C + Collection bus 4A, 4B Crosslinked interlayer 4S Upper interlayer 4 Intermediate interlayer 41 Lower tab 5A, 5B Seals

EXAMPLE OF IMPLEMENTATION

An example of a glass product according to the invention has been produced according to an assembly of a photovoltaic panel attached to a bare glass, as explained in FIG. 3A. The glass product produced is composed of:

-a lower barrier surface (IA) of rectangular tempered glass dimensions 1190mm (width) x 1200mm (length) x 4mm (thickness);

- a rectangular upper barrier surface (IB) in tempered glass, with the same dimensions as said lower barrier surface (IA);

-a rectangular opaque photovoltaic module (2A) with dimensions 1190mm x 70mm x 3mm (thickness);

-Of a non-tempered glass module (2B) of dimensions 1190mm x 1130mm x 2.7mm (thickness);

- a first collection bus (3A-) of the photovoltaic module (2) which is a metallic adhesive tape covered with a black masking liner 2.5mm wide and 120pm total thickness;

-a second collection bus (3A +) of the photovoltaic module (2) whose composition is identical to the previous one and its dimensions are 4mm in width and 120pm in total thickness;

- a first cross-linked spacer (4A) of 0.76mm EVA disposed between the lower faces of the assembly of the two adjoining modules (2A and 2B) and the lower barrier surface (IA);

-seals (5A) in GDP of dimensions 1.1mm (thickness) x 11mm (width) and ensuring the seal between the lower barrier surface (IA) and the lower faces of the contiguous modules (2A, 2B);

-a second crosslinked interlayer (4B) disposed between the upper faces of the adjoining modules (2A, 2B) and the upper barrier surface (IB), said interlayer comes from the crosslinking of the intermediate interlayer composed of a film d '' EVA 0.38mm thick and the upper interlayer composed of an EVA film 0.76mm thick during the temperature vacuum lamination process;

- seals (5B) identical to the seals (5A) and ensuring sealing between the upper barrier surface (IB) and the upper faces of the contiguous modules (2A, 2B).

For the realization of this module, it is necessary to assemble the various aforementioned elements, without a predefined order being absolutely necessary, then to the vacuum lamination of the pre-assembled assembly. The vacuum lamination process follows successive stages of evacuation, stabilization at room temperature, gradual rise in temperature in stages until reaching 140 ° C, and finally cooling with ventilation.

The invention achieves the set goals, by proposing a method of assembling joined modules of different thicknesses making it possible to obtain a large glass product, while avoiding breakage of said modules and the appearance of air bubbles during laminating said glass product.

Claims (12)

1 - Method for assembling a glass product with a view to its lamination, comprising the following steps: A) Supply at least: - two upper (IB) and lower (IA) barrier surfaces; - one or more seals (5A, 5B); - an upper spacer (4S); - a lower spacer (41); - one or more intermediate dividers (4); - At least two modules (2A, 2B) of different thicknesses (El, E2) such as E1> E2, joined to form a set of contiguous modules having an upper face and a lower face; B) Form the assembly such that: - said upper barrier surface (IB) is in contact with one or more seals (5B) and said upper interlayer (4S); - Said lower barrier surface (IA) is in contact with one or more seals (5A) and said lower interlayer (41); - all of said modules (2A, 2B) have an overall surface less than or equal to the smallest of the barrier surfaces; - The lower faces of said modules (2A, 2B) are in contact with the lower interlayer (41); characterized in that: the upper face (2Bs) of the thinner module (2B) (E2) is completely covered, near the surface of the joints (5B), by an intermediate interlayer (4), and the upper face (2AA) of the module ( 2A) of greater thickness (El) is partly covered by one or more intermediate interlayer (4) and partly by the upper interlayer (4S). 2 - A method of assembling a glass product according to claim 1, characterized in that the thickness E of the intermediate interlayer is chosen such that O, 8 * (E1 ~ E2) <E <1.2 * ( E1 ~ E2) so as to compensate for the difference between the thicknesses El, E2 of the two adjoining modules. 3 - A method of assembling a glass product according to any one of the preceding claims, characterized in that the spacers are composed of EVA encapsulation films. 4 - A method of assembling a glass product according to any one of the preceding claims, characterized in that the upper and lower barrier surfaces have the same shapes and the same dimensions. 5 - A method of assembling a glass product according to any one of the preceding claims, characterized in that one of the modules is a photovoltaic module. 6 - A method of assembling a glass product according to claim 5, characterized in that the module (s) jointiffs) to the photovoltaic module is (are) one (of) module (s) made of glass, plastic , rigid (s), semi-rigid (s) or flexible (s). 7 - A method of assembling a glass product according to claim 5, characterized in that the module (s) jointiffs) to the photovoltaic module is (are) one (of) module (s) works (s), such as an electrochromic module. 8 - A method of assembling a glass product according to any one of the preceding claims, characterized in that the barrier surfaces are toughened glasses. 9 - A method of assembling a glass product according to any one of claims 1 to 7, characterized in that the barrier surfaces are float glasses. 10 - Glass product characterized in that it is obtained using the assembly process according to any one of claims 1 to 9. 11 - Glass product according to claim 10, characterized in that the module is a photovoltaic module and plays the role of receiver in a wireless optical communication system. 12 - Glass product according to any one of claims 10 and 11, consisting of a stack comprising two upper barrier surfaces (IB) and lower (IA), at least two modules (2A, 2B) of respective thicknesses (El, E2 ) different such as E1> E2, joined to form a set of contiguous modules having an upper face and a lower face, an upper interlayer (4S) disposed between the upper barrier surface (IB) and the modules (2A, 2B), a lower interlayer (41) disposed between the lower barrier surface (IA) and the modules (2A, 2B), one or more seals (5A, 5B) arranged on the periphery of the product, characterized in that it further comprises one or more intermediate spacers (4) arranged astride the modules (2A, 2B) and having a thickness such that the thickness of the intermediate spacer portion (4) located opposite the thickest module (2A) is lower one value (El ~ E2) to the thickness of the intermediate interlayer portion (4) located opposite the thinner module (2B), so as to compensate for the differences in thickness between two modules (2A, 2B).