WO2020076150A1 - A coating composition and method of preparing thereof - Google Patents

A coating composition and method of preparing thereof Download PDF

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Publication number
WO2020076150A1
WO2020076150A1 PCT/MY2019/050071 MY2019050071W WO2020076150A1 WO 2020076150 A1 WO2020076150 A1 WO 2020076150A1 MY 2019050071 W MY2019050071 W MY 2019050071W WO 2020076150 A1 WO2020076150 A1 WO 2020076150A1
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WIPO (PCT)
Prior art keywords
zinc oxide
oxide particles
coating composition
solar module
light
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PCT/MY2019/050071
Other languages
French (fr)
Inventor
Andreas Schuett
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Lunar Progressive Sdn. Bhd.
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Publication of WO2020076150A1 publication Critical patent/WO2020076150A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/0216—Coatings
    • H01L31/02161—Coatings for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/02167—Coatings for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • H01L31/02168—Coatings for devices characterised by at least one potential jump barrier or surface barrier for solar cells the coatings being antireflective or having enhancing optical properties for the solar cells
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/61—Additives non-macromolecular inorganic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/22—Luminous paints
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/63—Additives non-macromolecular organic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/02—Use of particular materials as binders, particle coatings or suspension media therefor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
    • H01L31/055—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means where light is absorbed and re-emitted at a different wavelength by the optical element directly associated or integrated with the PV cell, e.g. by using luminescent material, fluorescent concentrators or up-conversion arrangements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/20—Optical components
    • H02S40/22—Light-reflecting or light-concentrating means
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2296—Oxides; Hydroxides of metals of zinc
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/06—Luminescent, e.g. electroluminescent, chemiluminescent materials containing organic luminescent materials
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K2211/00—Chemical nature of organic luminescent or tenebrescent compounds
    • C09K2211/10—Non-macromolecular compounds
    • C09K2211/1018—Heterocyclic compounds
    • C09K2211/1025—Heterocyclic compounds characterised by ligands
    • C09K2211/1044—Heterocyclic compounds characterised by ligands containing two nitrogen atoms as heteroatoms
    • C09K2211/1051—Heterocyclic compounds characterised by ligands containing two nitrogen atoms as heteroatoms with sulfur
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/52—PV systems with concentrators

Definitions

  • the present invention relates to a coating composition for use in a solar module, and more particularly to a coating composition that enhances conversion efficiency of the solar module.
  • Sunlight is a form of energy transformed from the Sun that is essential for sustaining all forms of life.
  • the sunlight is useful for supporting human activities, such as heating, cooking and drying.
  • solar energy deriving from the sunlight provides a cheaper and renewable alternative for generating electricity.
  • Solar power can generated using energy convertors such as photovoltaics and concentrated solar power systems.
  • the photovoltaics comprise solar panels for converting the sunlight directly into electricity, while the concentrated solar power systems use power plants to generate steam and then convert the steam into electricity using turbines. Both the energy convertors require at least one collector for capturing the sunlight.
  • a paper published in Energy Procedia 14, 2012, “Research on heat-transfer characteristics of solar cells and heat exchanger combined system and its optimization”, provides a solution to the abovementioned drawback using a combination of a solar cell and a solar heat exchanger.
  • the solar heat exchanger is installed on the back surface of a solar panel to enhance thermal efficiency and photovoltaic efficiency of the solar cell without changing structure of a solar board. Heat generated from the solar panel is taken away by flow of working fluid, exchanged between a pipe and a fin by convection and then brought into indoor to heat the room during winter, or to drive heat pumps to accomplish endothermic cooling during summer.
  • the efficiency of the energy convertors are highly depending on a combination of latitude and climate, and factors such as reflectance efficiency, thermodynamic efficiency, charge carrier separation efficiency and conduction efficiency values.
  • a recent study to improve performance of the energy convertors by incorporation of zinc oxide is disclosed in a paper published in Applied Physics Letter 92 (2008),“Improvement of organic solar cell performances using a zinc oxide anode coated by an ultrathin metallic layer”.
  • the paper provides an organic solar cell based on copper phthalocyanine (CuPc) layer as donor and fullerene as acceptor, and aluminium doped zinc oxide (ZnO : Al) as anode while having an ultrathin gold film being introduced among ZnO : Al and CuPc.
  • CuPc copper phthalocyanine
  • ZnO aluminium doped zinc oxide
  • the coating composition of the present invention can be installed easily on a solar module by a simple adhesion to a surface without the need to use a sophisticated technique.
  • the coating composition can increase wavelength of the light, such that light on the ultraviolet region can be utilized to generate electricity.
  • the primary object of the invention is to provide a coating composition that enhances conversion efficiency of a solar module, by incorporating zinc oxide particles that provide a randomized lasing effect, and a down-converting material that amplifies the wavelength of light.
  • Another object of the invention is to provide a coating composition that facilitates heat dissipation in a solar module such that to enhance efficiency of the solar module.
  • one object of the invention is to provide a method of producing a coating composition for use in a solar module, by annealing the zinc oxide particles to modify crystalline structure of the particles such that the particles transmit the light to an energy converting unit of the solar module by a randomized lasing effect.
  • one object of the invention is to provide a solar module having an application of the coating composition, where the coating composition is applied on a light receiving unit, or sandwiched between a functional unit and a light receiving unit of the solar module, using a simple coating or adhesion technique.
  • At least one of the preceding objects is met, in whole or in part, in which one aspect of the present invention describes a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprises: a substrate layer comprising zinc oxide particles deposited therein, and a luminescent down-converting material to increase wavelength of light.
  • the substrate layer comprises 0.1 to 50% by weight of the zinc oxide particles.
  • the substrate layer comprises 0.1 to 24% by weight of the zinc oxide particles.
  • the substrate layer comprises 36 to 50% by weight of the zinc oxide particles.
  • the zinc oxide particles have been annealed during production of the coating composition at a temperature ranging between substantially 50 to 400°C.
  • the zinc oxide particles have particle sizes ranging between 90 to 1500 nm.
  • Another aspect of the invention provides a method of producing a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprising the steps of: (a) annealing zinc oxide particles to obtain annealed zinc oxide particles; and (b) mixing the annealed zinc oxide particles with a precursor substrate solution to form a mixture, wherein step (b) comprises adding a luminescent down-converting material to increase wavelength of light.
  • step (b) is a step of mixing 0.1 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
  • step (b) is a step of mixing 0.1 to 24% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
  • step (b) is a step of mixing 36 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
  • step (a) is carried out at a temperature ranging between substantially 50 to 400°C.
  • step (a) produces the zinc oxide particles having particle sizes ranging between 90 to 1500 nm.
  • Another aspect of the invention provides a solar module having an application of the coating composition prepared according to preceding aspects.
  • the coating composition is deposited on a light receiving unit of the solar module.
  • the coating composition is sandwiched between at least one functional unit and a light receiving unit of the solar module.
  • Figure 1 shows a schematic diagram of a solar module (100) having a light receiving unit (102) and a functional unit (103), and a coating composition of the present invention (101) coated on top of the light receiving unit (102).
  • FIG. 2 shows a schematic diagram of a solar module (100) having a light receiving unit (102) and a functional unit (103), and a coating composition of the present invention (101) sandwiched therebetween.
  • the substrate layer of the coating composition is a medium for deposition of the zinc oxide particles and the down-converting material.
  • the substrate layer is a transparent layer having certain degree of transparency to allow light penetration such that the light reaches the zinc oxide particles and down-converting material.
  • the degree of transparency is 100%, and more preferably, the degree of transparency is 70 to 99%.
  • the substrate layer can be in a form of liquid, semi-solid or solid, applied on a surface of a glass, a polymer, a semiconductor, a metal, an anti-reflection coating, or a ceramic.
  • the substrate layer can be a lacquer, a gel, a film, a polymer substrate or a substrate having at least one tacky surface.
  • the substrate layer can be a tape having substantive adhesive properties to adhere to a surface.
  • the coating composition comprises 0.1 to 50% by weight of the zinc oxide particles deposited within the substrate layer.
  • the zinc oxide particles in the coating composition is deposited at an amount of 0.1 to 24% by weight, or 36 to 50%. More preferably, the coating composition comprises 5 to 15% by weight of the zinc oxide particles, to meet a standard based on the degree of transparency.
  • the zinc oxide particles have been annealed during production of the coating composition at a temperature ranging between substantially 50 to 400°C.
  • the zinc oxide particles have particle sizes ranging between 90 to 1500 nm, and more particularly having a modified surface morphology that capable of amplifying incident light by a randomized lasing effect.
  • the zinc oxide particles having shapes of spherical, rod or crystal rod having six to ten facets can be used for such an application. More particularly, energy supplied during the annealing process accelerates atom migration to a favourable energy position and then rearranges the atoms to form fine crystalline structure. Furthermore, oxygen composition on the particle surface is altered and interstitial oxygen atoms are introduced to the particle surface to form a space charge region on the zinc oxide particles.
  • the randomized lasing effect in the zinc oxide particles enables the coating composition to act as a supplementary layer for a solar module to enhance conversion efficiency, particularly heat to light conversion efficiency.
  • the coating composition comprises the luminescent down-converting material deposited within the substrate layer.
  • the coating composition comprises 0.1 to 40% by weight of the down-converting material.
  • Quinine sulphate is a preferred down-converting material, but other materials such as xanthine, cyanine, squaraine, naphthalene, coumarin, oxadiazole, anthracene, pyrene, oxazine, acridine, arylmethin, tetrapyrrole, or any of their derivative can also be used for such application.
  • the down-converting material absorbs light and re-emits the light at a lower frequency and energy level.
  • the down-converting material absorbs light having wavelength shorter than 400 nm and re-emits the light at a wavelength ranging from 400 to 1000 nm.
  • ultraviolet ray that are generally having wavelength shorter than 400 nm can also be utilized by the solar module to generate electricity.
  • the down-converting material also capable of increasing wavelength of the light re-emitted from the zinc oxide particles.
  • the down-converting material re-emits the light at a higher wavelength and a lower energy level, allowing heat to dissipate at a higher rate.
  • the low wavelength energy is transformed into light, instead of being converted into a form of heat.
  • the coating composition prevents heat retention within the solar module that could possibly affecting its heat to light conversion efficiency.
  • the zinc oxide particles are also contributing to better heat dissipation in the coating composition, by forming an inversion layer via the randomized lasing effect.
  • the inversion layer is a p-doped area having more electrons in conduction band than holes in valence band, where the excited electrons are to be re emitted in a form of light by a stimulated emission.
  • the coating composition is in a form of liquid, semi-solid or solid.
  • the coating composition can be deposited on a light receiving unit of a solar module, or sandwiched between at least one functional unit and a light receiving unit of a solar module.
  • the functional unit can be an ethylene vinyl acetate (EVA) unit or a solar cell.
  • EVA ethylene vinyl acetate
  • the coating composition can also be applied to a module glass of a solar module, or mixed with EVA encapsulating materials or encapsulation stacks for forming the functional unit.
  • the coating composition is also useful for a lighting application such as a light-emitting diode, a light bulb, a laser, or a sensor application such as a photomultiplier.
  • the coating composition can also be applied to a green house, where presence of the down-converting material converts the wavelength of the light to a wavelength beneficial for plant growth.
  • the coating composition can be coated on the green house or optionally incorporated into a polymer for manufacturing the green house.
  • the coating composition, particularly in the solid form, can also acts as a water resistance barrier to the applied surface.
  • the coating composition has a heat to light conversion efficiency of 5 to 865 times input to output.
  • the coating composition induces light re-emission and prevents heat retention, due to presence of the zinc oxide particles and the down-converting material deposited within the substrate layer.
  • the heat to light conversion efficiency may vary according to the amount of the zinc oxide particles and the down-converting material.
  • the coating composition has a light conversion efficiency up to substantially 157 times input to output, and a photocurrent temperature coefficient of 5 to 5.5. High temperature generally negatively affects photocurrent temperature coefficient of a solar cell, where high temperature may render voltage loss and power loss, and maximum power point can be measured up to -0.4l%/K.
  • the coating composition of the present invention is capable of turning the maximum power point to a positive value, and then inducing higher output power when high temperature is applied to a solar cell coated with the composition.
  • the present invention is also characterized by a method of producing a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprising the steps of: (a) annealing zinc oxide particles to obtain annealed zinc oxide particles; and (b) mixing the annealed zinc oxide particles with a precursor substrate solution to form a mixture, wherein step (b) comprises adding a luminescent down-converting material to increase wavelength of light.
  • the method comprises steps of (a) annealing the zinc oxide particles to obtain the annealed zinc oxide particles, and (b) mixing the annealed zinc oxide particles with a precursor substrate solution to form a mixture.
  • step (a) is carried out at a temperature ranging between substantially 50 to 400°C.
  • the step (a) produces the zinc oxide particles having particle sizes ranging between 90 to 1500 nm.
  • step (b) is a step of mixing 0.1 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture. More preferably, step (b) is mixing 0.1 to 24% by weight, or 36 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
  • the annealed zinc oxide particles are mixed at an amount of 5 to 15% by weight.
  • Step (b) also comprises adding the luminescent down converting material to the precursor substrate solution, at an amount of 0.1 to 40% by weight.
  • the method comprises a step of pulverizing or sieving the annealed zinc oxide particles into finer particles prior to step (b) to eliminate agglomerated zinc oxide particles. Such step may be vital to ensure the coating composition has a certain degree of transparency to arrive to its best performance.
  • step (b) can be carried out in a homogenizer or a mixer to ensure homogeneity of the annealed zinc oxide particles and the down-converting material deposited within the coating composition.
  • the mixture comprising the annealed zinc oxide, the down-converting material and the precursor substrate solution can be applied directly to a surface of a glass, a polymer, a semiconductor, a metal, an anti-reflection coating, or a ceramic, or optionally set to form a solid composition or a semi-solid composition.
  • the mixture can also be formed into a tape having substantive adhesive properties to adhere to a surface.
  • the mixture can be applied to a finished solar module, particularly on a module glass of the solar module, or incorporated into an encapsulating material of a solar module.
  • the mixture can also be sandwiched between at least one functional unit and a light receiving unit of a solar module during production of the solar module.
  • the precursor substrate solution is a medium for depositing the annealed zinc oxide particles and the down-converting material, such that the mixture forms the coating composition.
  • the mixture that sets into a solid composition is useful to act as a water resistance barrier to protect the applied surface.
  • the present invention also describes a solar module having an application of the coating composition prepared according to the previous embodiments.
  • the coating composition is deposited on a light receiving unit of the solar module.
  • the light receiving unit is a module glass.
  • the coating composition can also be deposited on an opposite side of the light receiving unit, facing other functional units of the solar module.
  • the coating composition can also be sandwiched between at least one functional unit and a light receiving unit of the solar module, formed into an independent layer sandwiched therebetween, or mixed with raw ingredients that form the functional unit.
  • the coating composition is incorporated to an encapsulating material, such as EVA, of a solar module. Such arrangement permits better light penetration to the functional unit and then converts the light into electricity.
  • the solar module having application of the coating composition has a heat to light conversion efficiency of 5 to 865 times input to output.
  • the presence of the zinc oxide particles and the luminescent down-converting material deposited within the substrate layer induce light re-emission in the coating composition and prevents heat retention in the solar module.
  • the zinc oxide particles that have been annealed during production of the coating composition at a temperature ranging between substantially 50 to 400°C are having particle sizes ranging between 90 to 1500 nm. More particularly, the annealed zinc oxide particles induce randomized lasing effect that contributes to the heat to light conversion efficiency of the solar module.
  • the down-converting material re-emits light at a higher wavelength and lower energy level such that the low wavelength energy is transformed into light, instead of being converted into a form of heat.
  • the solar module has a light conversion efficiency up to substantially 157 times input to output, and a photocurrent temperature coefficient of 5 to 5.5.
  • the heat to light conversion efficiency of the solar module may vary according to the amount of the zinc oxide particles and the down-converting material in the coating composition. Arrangement of the coating composition within the solar module does not affect the efficiency of the solar module.
  • EXAMPLE 1 Commercially available zinc oxide particles were subjected to various annealing condition. The annealing process was conducted by subjecting the zinc oxide particles under ambient conditions in an oven based on temperature and time as shown in Table 1. The annealed zinc oxide was mixed with a mixture comprising water and lacquer at a ratio of 50:50 and applied on a transparent polymer sheet placing on a mini module solar cell on an encapsulated solar cell having dimension of 15.6 cm x 15.6 cm to measure light conversion efficiency. A converted module is soldered on top and bottom of the mini module solar cell connecting to metal strings that lead through the encapsulated module such the converted module electrically connected to the encapsulated module.
  • Table 1 Relationship between annealing condition of zinc oxide particles with photocurrent coefficient.
  • Zinc oxide particles that have been annealed at l00°C was used for measuring photocurrent temperature coefficient of the coating composition under an application condition at a temperature ranging from 25 to 50°C.
  • a reference sample was prepared by coating a pristine lacquer layer on a transparent film, and a sample resembling the coating composition of the present invention was prepared by a lacquer comprising zinc oxide particles.
  • the reference sample and the sample are placed on a mini module solar cell, and the mini module is placed on a temperature controlled copper plate, where simple current-voltage (IV)-curve measurement was obtained under 1/3 sun illumination represented by halogen lamps.
  • Tc is the Temperature coefficient in l/°C
  • IPh(T) is he measured photocurrent at temperature T in mA
  • Tl and T2 are different temperatures in °C with T2>Tl.
  • Table 2 Effects of temperature on temperature coefficient of the coating composition and a reference sample.
  • the temperature coefficient obtained from the experiment is 5 to 789.5%.

Abstract

A coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprises: a substrate layer comprising zinc oxide particles deposited therein, and a luminescent down-converting material to increase wavelength of light.

Description

A COATING COMPOSITION AND METHOD OF PREPARING THEREOF
FIELD OF INVENTION
The present invention relates to a coating composition for use in a solar module, and more particularly to a coating composition that enhances conversion efficiency of the solar module.
BACKGROUND OF THE INVENTION
Sunlight is a form of energy transformed from the Sun that is essential for sustaining all forms of life. The sunlight is useful for supporting human activities, such as heating, cooking and drying. Furthermore, solar energy deriving from the sunlight provides a cheaper and renewable alternative for generating electricity. Solar power can generated using energy convertors such as photovoltaics and concentrated solar power systems. Particularly, the photovoltaics comprise solar panels for converting the sunlight directly into electricity, while the concentrated solar power systems use power plants to generate steam and then convert the steam into electricity using turbines. Both the energy convertors require at least one collector for capturing the sunlight.
Nevertheless, current technologies for generating solar power possess drawbacks, particularly on poor heat dissipation that could deteriorate energy conversion efficiency of the energy convertors. The energy conversion efficiency is negatively affected when the solar panel absorbs heat from the sunlight. Output current in the photovoltaic increases exponentially along temperature increase, thereby causing voltage output to reduce linearly. Several precautions suggested to minimize the negative effects are installing solar panels a few inches above the roof to allow air ventilation to cool the panels, installing move components like inverters and combiners into shaded area behind arrays of the panels, and constructing the solar panels using light-coloured materials to reduce heat absorption.
A paper published in Energy Procedia 14, 2012, “Research on heat-transfer characteristics of solar cells and heat exchanger combined system and its optimization”, provides a solution to the abovementioned drawback using a combination of a solar cell and a solar heat exchanger. Particularly, the solar heat exchanger is installed on the back surface of a solar panel to enhance thermal efficiency and photovoltaic efficiency of the solar cell without changing structure of a solar board. Heat generated from the solar panel is taken away by flow of working fluid, exchanged between a pipe and a fin by convection and then brought into indoor to heat the room during winter, or to drive heat pumps to accomplish endothermic cooling during summer.
Furthermore, the efficiency of the energy convertors are highly depending on a combination of latitude and climate, and factors such as reflectance efficiency, thermodynamic efficiency, charge carrier separation efficiency and conduction efficiency values. A recent study to improve performance of the energy convertors by incorporation of zinc oxide is disclosed in a paper published in Applied Physics Letter 92 (2008),“Improvement of organic solar cell performances using a zinc oxide anode coated by an ultrathin metallic layer”. The paper provides an organic solar cell based on copper phthalocyanine (CuPc) layer as donor and fullerene as acceptor, and aluminium doped zinc oxide (ZnO : Al) as anode while having an ultrathin gold film being introduced among ZnO : Al and CuPc.
Therefore, there exists a need to provide a coating composition for use in a solar module that simultaneously enhance light conversion efficiency and heat conversion efficiency by a simple intervention. The coating composition of the present invention can be installed easily on a solar module by a simple adhesion to a surface without the need to use a sophisticated technique. In addition, the coating composition can increase wavelength of the light, such that light on the ultraviolet region can be utilized to generate electricity.
SUMMARY OF INVENTION
The primary object of the invention is to provide a coating composition that enhances conversion efficiency of a solar module, by incorporating zinc oxide particles that provide a randomized lasing effect, and a down-converting material that amplifies the wavelength of light.
Another object of the invention is to provide a coating composition that facilitates heat dissipation in a solar module such that to enhance efficiency of the solar module.
Still, one object of the invention is to provide a method of producing a coating composition for use in a solar module, by annealing the zinc oxide particles to modify crystalline structure of the particles such that the particles transmit the light to an energy converting unit of the solar module by a randomized lasing effect.
Yet, one object of the invention is to provide a solar module having an application of the coating composition, where the coating composition is applied on a light receiving unit, or sandwiched between a functional unit and a light receiving unit of the solar module, using a simple coating or adhesion technique.
At least one of the preceding objects is met, in whole or in part, in which one aspect of the present invention describes a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprises: a substrate layer comprising zinc oxide particles deposited therein, and a luminescent down-converting material to increase wavelength of light.
According to a feature of this aspect of the invention, the substrate layer comprises 0.1 to 50% by weight of the zinc oxide particles.
According to another feature of this aspect of the invention, the substrate layer comprises 0.1 to 24% by weight of the zinc oxide particles.
According to another feature of this aspect of the invention, the substrate layer comprises 36 to 50% by weight of the zinc oxide particles.
According to a still further feature of this aspect of the invention, the zinc oxide particles have been annealed during production of the coating composition at a temperature ranging between substantially 50 to 400°C.
According to yet another feature of this aspect of the invention, the zinc oxide particles have particle sizes ranging between 90 to 1500 nm.
Another aspect of the invention provides a method of producing a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprising the steps of: (a) annealing zinc oxide particles to obtain annealed zinc oxide particles; and (b) mixing the annealed zinc oxide particles with a precursor substrate solution to form a mixture, wherein step (b) comprises adding a luminescent down-converting material to increase wavelength of light.
According to a feature of this aspect of the invention, step (b) is a step of mixing 0.1 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
According to another feature of this aspect of the invention, step (b) is a step of mixing 0.1 to 24% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture. According to another feature of this aspect of the invention, step (b) is a step of mixing 36 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
According to a still further feature of this aspect of the invention, step (a) is carried out at a temperature ranging between substantially 50 to 400°C.
According to yet another feature of this aspect of the invention, step (a) produces the zinc oxide particles having particle sizes ranging between 90 to 1500 nm.
Another aspect of the invention provides a solar module having an application of the coating composition prepared according to preceding aspects.
Preferably, the coating composition is deposited on a light receiving unit of the solar module.
Preferably, the coating composition is sandwiched between at least one functional unit and a light receiving unit of the solar module.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiment described herein is not intended as limitations on the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawing the preferred embodiments from an inspection of which when considered in connection with the following description, the invention, its construction and operation and many of its advantages would be readily understood and appreciated.
Figure 1 shows a schematic diagram of a solar module (100) having a light receiving unit (102) and a functional unit (103), and a coating composition of the present invention (101) coated on top of the light receiving unit (102).
Figure 2 shows a schematic diagram of a solar module (100) having a light receiving unit (102) and a functional unit (103), and a coating composition of the present invention (101) sandwiched therebetween. DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the invention shall be described according to the preferred embodiments of the present invention and by referring to the accompanying description and drawings. However, it is to be understood that limiting the description to the preferred embodiments of the invention is merely to facilitate discussion of the present invention and it is envisioned that those skilled in the art may devise various modifications without departing from the scope of the appended claim.
The present invention discloses a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprises a substrate layer comprising zinc oxide particles deposited therein, and a luminescent down-converting material to increase wavelength of light.
According to one of the preferred embodiments of the present invention, the substrate layer of the coating composition is a medium for deposition of the zinc oxide particles and the down-converting material. The substrate layer is a transparent layer having certain degree of transparency to allow light penetration such that the light reaches the zinc oxide particles and down-converting material. Preferably, the degree of transparency is 100%, and more preferably, the degree of transparency is 70 to 99%. The substrate layer can be in a form of liquid, semi-solid or solid, applied on a surface of a glass, a polymer, a semiconductor, a metal, an anti-reflection coating, or a ceramic. Particularly, the substrate layer can be a lacquer, a gel, a film, a polymer substrate or a substrate having at least one tacky surface. Optionally, the substrate layer can be a tape having substantive adhesive properties to adhere to a surface.
According to the preferred embodiment of the present invention, the coating composition comprises 0.1 to 50% by weight of the zinc oxide particles deposited within the substrate layer. Preferably, the zinc oxide particles in the coating composition is deposited at an amount of 0.1 to 24% by weight, or 36 to 50%. More preferably, the coating composition comprises 5 to 15% by weight of the zinc oxide particles, to meet a standard based on the degree of transparency. In addition, the zinc oxide particles have been annealed during production of the coating composition at a temperature ranging between substantially 50 to 400°C. Particularly, the zinc oxide particles have particle sizes ranging between 90 to 1500 nm, and more particularly having a modified surface morphology that capable of amplifying incident light by a randomized lasing effect. The zinc oxide particles having shapes of spherical, rod or crystal rod having six to ten facets can be used for such an application. More particularly, energy supplied during the annealing process accelerates atom migration to a favourable energy position and then rearranges the atoms to form fine crystalline structure. Furthermore, oxygen composition on the particle surface is altered and interstitial oxygen atoms are introduced to the particle surface to form a space charge region on the zinc oxide particles. The randomized lasing effect in the zinc oxide particles enables the coating composition to act as a supplementary layer for a solar module to enhance conversion efficiency, particularly heat to light conversion efficiency. According to another preferred embodiment of the present invention, the coating composition comprises the luminescent down-converting material deposited within the substrate layer. Preferably, the coating composition comprises 0.1 to 40% by weight of the down-converting material. Quinine sulphate is a preferred down-converting material, but other materials such as xanthine, cyanine, squaraine, naphthalene, coumarin, oxadiazole, anthracene, pyrene, oxazine, acridine, arylmethin, tetrapyrrole, or any of their derivative can also be used for such application. The down-converting material absorbs light and re-emits the light at a lower frequency and energy level. Particularly, the down-converting material absorbs light having wavelength shorter than 400 nm and re-emits the light at a wavelength ranging from 400 to 1000 nm. As such, ultraviolet ray that are generally having wavelength shorter than 400 nm can also be utilized by the solar module to generate electricity. The down-converting material also capable of increasing wavelength of the light re-emitted from the zinc oxide particles.
As set forth in the previous embodiment, the down-converting material re-emits the light at a higher wavelength and a lower energy level, allowing heat to dissipate at a higher rate. The low wavelength energy is transformed into light, instead of being converted into a form of heat. Thus, the coating composition prevents heat retention within the solar module that could possibly affecting its heat to light conversion efficiency. On the other hand, the zinc oxide particles are also contributing to better heat dissipation in the coating composition, by forming an inversion layer via the randomized lasing effect. The inversion layer is a p-doped area having more electrons in conduction band than holes in valence band, where the excited electrons are to be re emitted in a form of light by a stimulated emission. Higher temperature stimulates formation of the electrons in the conduction band based on a Bolzmann constant, where concentration of the electrons is exponentially dependent on temperature. Thus, increased amount of electrons within the inversion layer induces re-emission of light by the stimulated emission. As such, the activated heat dissipation mechanism in the coating composition prevents heat retention and provides a cooling effect to the solar module.
In accordance with another preferred embodiment of the present invention, the coating composition is in a form of liquid, semi-solid or solid. The coating composition can be deposited on a light receiving unit of a solar module, or sandwiched between at least one functional unit and a light receiving unit of a solar module. Particularly, the functional unit can be an ethylene vinyl acetate (EVA) unit or a solar cell. The coating composition can also be applied to a module glass of a solar module, or mixed with EVA encapsulating materials or encapsulation stacks for forming the functional unit. The coating composition is also useful for a lighting application such as a light-emitting diode, a light bulb, a laser, or a sensor application such as a photomultiplier. In addition, the coating composition can also be applied to a green house, where presence of the down-converting material converts the wavelength of the light to a wavelength beneficial for plant growth. Particularly, the coating composition can be coated on the green house or optionally incorporated into a polymer for manufacturing the green house. The coating composition, particularly in the solid form, can also acts as a water resistance barrier to the applied surface.
According to the preferred embodiment of the present invention, the coating composition has a heat to light conversion efficiency of 5 to 865 times input to output. The coating composition induces light re-emission and prevents heat retention, due to presence of the zinc oxide particles and the down-converting material deposited within the substrate layer. The heat to light conversion efficiency may vary according to the amount of the zinc oxide particles and the down-converting material. Preferably, the coating composition has a light conversion efficiency up to substantially 157 times input to output, and a photocurrent temperature coefficient of 5 to 5.5. High temperature generally negatively affects photocurrent temperature coefficient of a solar cell, where high temperature may render voltage loss and power loss, and maximum power point can be measured up to -0.4l%/K. The coating composition of the present invention is capable of turning the maximum power point to a positive value, and then inducing higher output power when high temperature is applied to a solar cell coated with the composition.
The present invention is also characterized by a method of producing a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprising the steps of: (a) annealing zinc oxide particles to obtain annealed zinc oxide particles; and (b) mixing the annealed zinc oxide particles with a precursor substrate solution to form a mixture, wherein step (b) comprises adding a luminescent down-converting material to increase wavelength of light.
According to the preferred embodiment of the present invention, the method comprises steps of (a) annealing the zinc oxide particles to obtain the annealed zinc oxide particles, and (b) mixing the annealed zinc oxide particles with a precursor substrate solution to form a mixture. Preferably, step (a) is carried out at a temperature ranging between substantially 50 to 400°C. The step (a) produces the zinc oxide particles having particle sizes ranging between 90 to 1500 nm. Preferably, step (b) is a step of mixing 0.1 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture. More preferably, step (b) is mixing 0.1 to 24% by weight, or 36 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture. Most preferably, the annealed zinc oxide particles are mixed at an amount of 5 to 15% by weight. Step (b) also comprises adding the luminescent down converting material to the precursor substrate solution, at an amount of 0.1 to 40% by weight. Particularly, the method comprises a step of pulverizing or sieving the annealed zinc oxide particles into finer particles prior to step (b) to eliminate agglomerated zinc oxide particles. Such step may be vital to ensure the coating composition has a certain degree of transparency to arrive to its best performance. Optionally, step (b) can be carried out in a homogenizer or a mixer to ensure homogeneity of the annealed zinc oxide particles and the down-converting material deposited within the coating composition.
According to another preferred embodiment of the present invention, the mixture comprising the annealed zinc oxide, the down-converting material and the precursor substrate solution, can be applied directly to a surface of a glass, a polymer, a semiconductor, a metal, an anti-reflection coating, or a ceramic, or optionally set to form a solid composition or a semi-solid composition. The mixture can also be formed into a tape having substantive adhesive properties to adhere to a surface. Furthermore, the mixture can be applied to a finished solar module, particularly on a module glass of the solar module, or incorporated into an encapsulating material of a solar module. The mixture can also be sandwiched between at least one functional unit and a light receiving unit of a solar module during production of the solar module. The precursor substrate solution is a medium for depositing the annealed zinc oxide particles and the down-converting material, such that the mixture forms the coating composition. In addition, the mixture that sets into a solid composition is useful to act as a water resistance barrier to protect the applied surface.
The present invention also describes a solar module having an application of the coating composition prepared according to the previous embodiments. Preferably, the coating composition is deposited on a light receiving unit of the solar module. Particularly, the light receiving unit is a module glass. The coating composition can also be deposited on an opposite side of the light receiving unit, facing other functional units of the solar module. The coating composition can also be sandwiched between at least one functional unit and a light receiving unit of the solar module, formed into an independent layer sandwiched therebetween, or mixed with raw ingredients that form the functional unit. For instance, the coating composition is incorporated to an encapsulating material, such as EVA, of a solar module. Such arrangement permits better light penetration to the functional unit and then converts the light into electricity. According to one of the preferred embodiments of the present invention, the solar module having application of the coating composition has a heat to light conversion efficiency of 5 to 865 times input to output. The presence of the zinc oxide particles and the luminescent down-converting material deposited within the substrate layer, induce light re-emission in the coating composition and prevents heat retention in the solar module. Particularly, the zinc oxide particles that have been annealed during production of the coating composition at a temperature ranging between substantially 50 to 400°C, are having particle sizes ranging between 90 to 1500 nm. More particularly, the annealed zinc oxide particles induce randomized lasing effect that contributes to the heat to light conversion efficiency of the solar module. On the other hand, the down-converting material re-emits light at a higher wavelength and lower energy level such that the low wavelength energy is transformed into light, instead of being converted into a form of heat. Preferably, the solar module has a light conversion efficiency up to substantially 157 times input to output, and a photocurrent temperature coefficient of 5 to 5.5. The heat to light conversion efficiency of the solar module may vary according to the amount of the zinc oxide particles and the down-converting material in the coating composition. Arrangement of the coating composition within the solar module does not affect the efficiency of the solar module.
The present disclosure includes as contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a degree of particularly, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangements of parts may be resorted to without departing from the scope of the invention.
EXAMPLE
The following non-limiting example has been carried out to illustrate the preferred embodiments of the invention.
EXAMPLE 1 Commercially available zinc oxide particles were subjected to various annealing condition. The annealing process was conducted by subjecting the zinc oxide particles under ambient conditions in an oven based on temperature and time as shown in Table 1. The annealed zinc oxide was mixed with a mixture comprising water and lacquer at a ratio of 50:50 and applied on a transparent polymer sheet placing on a mini module solar cell on an encapsulated solar cell having dimension of 15.6 cm x 15.6 cm to measure light conversion efficiency. A converted module is soldered on top and bottom of the mini module solar cell connecting to metal strings that lead through the encapsulated module such the converted module electrically connected to the encapsulated module. The converted module was placed in a solar cell local characterization (CELLO) setup, where simple current- voltage (IV)-curve measurement was obtained under 1/3 sun illumination represented by halogen lamps. Photocurrent value was obtained from the IV-curve at voltage = 0. Additional light conversion efficiency calculated by % is relative photocurrent change of the film dispersed with zinc oxide particles annealed with different condition divided by a reference film dispersed with only a pristine substrate layer. Annealing temperature above 500°C jeopardizes efficiency of the annealed zinc oxide.
Table 1: Relationship between annealing condition of zinc oxide particles with photocurrent coefficient.
Figure imgf000014_0001
Figure imgf000015_0001
EXAMPLE 2
Zinc oxide particles that have been annealed at l00°C was used for measuring photocurrent temperature coefficient of the coating composition under an application condition at a temperature ranging from 25 to 50°C. A reference sample was prepared by coating a pristine lacquer layer on a transparent film, and a sample resembling the coating composition of the present invention was prepared by a lacquer comprising zinc oxide particles. The reference sample and the sample are placed on a mini module solar cell, and the mini module is placed on a temperature controlled copper plate, where simple current-voltage (IV)-curve measurement was obtained under 1/3 sun illumination represented by halogen lamps. The photocurrent temperature coefficient was calculating using Equation 1: Tc= { [IPh(T2)- IPh(Tl)]/ IPh(Tl)}/(T2-Tl) (Equation 1)
, where Tc is the Temperature coefficient in l/°C, IPh(T) is he measured photocurrent at temperature T in mA, and Tl and T2 are different temperatures in °C with T2>Tl. The result is as shown in Table 2. The coating composition shows 3.81% improvement relative to the reference sample. Table 2: Effects of temperature on temperature coefficient of the coating composition and a reference sample.
Figure imgf000016_0001
EXAMPLE 3
Based on Table 1, light conversion efficiency is also represented as photocurrent improvement, where the range is 1 to 157.9%. Relative temperature coefficient (Tc) improvement is deduced from the photocurrent improvement, using Equation 2: Tc = 5 x photocurrent improvement (Equation 2)
As a result, the temperature coefficient obtained from the experiment is 5 to 789.5%.

Claims

1. A coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprises:
a substrate layer comprising zinc oxide particles deposited therein, and a luminescent down-converting material to increase wavelength of light.
2. A composition according to claim 1, wherein the substrate layer comprises 0.1 to 50% by weight of the zinc oxide particles.
3. A composition according to claim 1 or 2, wherein the substrate layer comprises 0.1 to 24% by weight of the zinc oxide particles.
4. A composition according to claim 1 or 2, wherein the substrate layer comprises 36 to 50% by weight of the zinc oxide particles.
5. A composition according to any one of claims 1 to 4, wherein the zinc oxide particles have been annealed during production of the coating composition at a temperature ranging between substantially 50 to 400°C.
6. A composition according to claim 5, wherein the zinc oxide particles have particle sizes ranging between 90 to 1500 nm.
7. A method of producing a coating composition having a heat to light conversion efficiency of 5 to 865 times input to output for use in a solar module comprising the steps of:
(a) annealing zinc oxide particles to obtain annealed zinc oxide; and
(b) mixing the annealed zinc oxide particles with a precursor substrate solution to form a mixture;
wherein step (b) comprises adding a luminescent down-converting material to increase wavelength of light.
8. A method according to claim 7, wherein step (b) is a step of mixing 0.1 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
9. A method according to claim 7 or 8, wherein step (b) is a step of mixing 0.1 to 24% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
10. A method according to claim 7 or 8, wherein step (b) is a step of mixing 36 to 50% by weight of the annealed zinc oxide particles with the precursor substrate solution to form the mixture.
11. A method according to any one of claims 7 to 10, wherein step (a) is carried out at a temperature ranging between substantially 50 to 400°C.
12. A method according to any one of claims 7 to 11, wherein step (a) produces the zinc oxide particles having particle sizes ranging between 90 to 1500 nm.
13. A solar module having an application of the coating composition prepared according to any of the preceding claims.
14. A solar module according to claim 13, wherein the coating composition is deposited on a light receiving unit of the solar module.
15. A solar module according to claim 13, wherein the coating composition is sandwiched between at least one functional unit and a light receiving unit of the solar module.
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