Production method of single-suede ultra-white patterned glass

Abstract

The invention discloses a production method of single-suede ultra-white patterned glass, and relates to the technical field of photovoltaic glass production, and the technical key points are as follows: raw materials are subjected to iron removal and crushing treatment to obtain powder, the powder is added into a melting kiln to be smelted, and a clarifying agent is added to obtain molten glass; the molten glass flows into a tin bath to form a glass tape, and the glass tape is subjected to calendaring molding by using an embossing roller to form a single suede surface and an embossed surface; annealing the semi-finished glass, and naturally cooling to obtain a glass finished product; the problems that after the iron content in the ultra-white patterned glass raw material reaches a certain limit value, the effect of further reducing the iron content is no longer remarkable for improving the light transmittance, and the cost is high are solved; according to the invention, while the same light transmittance parameter is achieved, the obvious cost advantage is shown.

Description

Technical Field

[0001] The invention relates to the technical field of photovoltaic glass production, and in particular to a production method of single-velvet ultra-white patterned glass. Background Art

[0002] Today, with the rapid development of photovoltaic technology, solar cells are an important representative of renewable energy, and their packaging materials, ultra-white embossed glass, play a vital role. This special type of glass is not only used to encapsulate solar cells, but also undertakes multiple tasks such as protecting the cells and improving the photoelectric conversion efficiency.

[0003] The uniqueness of ultra-clear patterned glass lies in its extremely low iron content and extremely high light transmittance. This is because during the production process, ore raw materials with extremely low iron content are used to replace traditional glass ore. This choice of raw materials fundamentally reduces the iron content in the glass, thereby significantly improving its light transmittance.

[0004] The process of manufacturing ultra-clear embossed glass is similar to that of ordinary embossed glass, but more sophisticated. During the production process, a special embossing roller is used to press various patterns on the surface of ultra-clear glass, such as hexagons, quadrilaterals, flat hexagons and diamonds. These patterns not only enhance the aesthetics of the glass, but also improve its impact resistance and anti-slip properties, further increasing its application value in the field of solar cell encapsulation.

[0005] However, although ultra-white embossed glass has achieved certain performance advantages, there are still some technical challenges in practical applications. First of all, although the light transmittance of ultra-white embossed glass can be effectively improved by reducing the iron content in the raw materials. However, after reaching a certain limit, this method will not only increase production costs, but also the effect of improving product quality will no longer be obvious. In addition, due to the particularity of the raw materials, the production cost of ultra-white embossed glass itself is higher than that of ordinary glass, which also limits its application in a wider range of fields. Summary of the invention

[0006] In view of the problem that in the prior art, after the iron content in the raw material of ultra-clear embossed glass reaches a certain limit, the effect of further reducing the iron content on improving the transmittance is no longer significant, and the cost is high, the purpose of the present invention is to provide an innovative production method for single-velvet ultra-clear embossed glass. This method aims to further improve the transmittance of ultra-clear embossed glass by a non-reducing iron content approach, and while achieving the same transmittance parameters, it shows a significant cost advantage.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A method for producing single-velvet ultra-clear patterned glass comprises the following steps:

[0009] S1. Deironing and pulverizing: deironing and pulverizing the raw materials to obtain raw material powder;

[0010] S2, melting: adding the raw material powder into a glass melting furnace for melting, and adding a clarifier to obtain molten glass;

[0011] S3, tin bath forming: the molten glass flows into the tin bath through the flow channel, and the molten glass is spread out to form a glass ribbon;

[0012] S4, embossing: using a special embossing roller to roll the glass ribbon, forming a single velvet surface on one side of the glass ribbon and an embossed surface on the other side of the glass ribbon, wherein the embossed surface is composed of a plurality of pointed cone-shaped embossed grooves, and the plurality of embossed grooves are evenly distributed on the embossed surface, to obtain a semi-finished glass;

[0013] S5, annealing and cooling: after rolling and forming, the semi-finished glass is immediately transferred to a resistance furnace for annealing. After annealing, the semi-finished glass is cooled by natural cooling to obtain a finished glass product.

[0014] By adopting the above scheme, firstly, steps S1 to S2 involve iron removal, crushing and smelting of raw materials, which are conventional steps in glass production and are mainly used to ensure the purity of glass and the quality of molten glass after melting; although iron removal treatment can reduce the iron content in glass and thus improve light transmittance; next, tin bath forming in step S3 is a standard process in glass production, which spreads the glass liquid to form a glass ribbon and has no direct effect on light transmittance; embossing forming in step S4 uses a special embossing roller to roll the glass ribbon to form a single velvet surface and an embossed surface composed of multiple conical embossing grooves; this step has a potential impact on light transmittance; the conical embossing groove design can reduce the reflection of light on the glass surface and increase the transmission of light inside the glass, thereby improving light transmittance; this design does not rely on reducing the iron content, but achieves light transmittance by changing the microstructure of the glass surface improvement; finally, annealing and cooling in step S5 are necessary steps in glass production, which are used to eliminate residual stress in the glass and improve the stability of the glass; these steps have little effect on the transmittance; from a cost perspective, although the special embossing roller may require a certain initial investment, once it is put into production, its cost will be spread over a large number of products, thereby reducing the cost of a single product; in addition, since it is not necessary to increase the transmittance by reducing the iron content, the cost of iron removal equipment and raw materials can be saved, further improving the overall cost advantage; in summary, the technical solution uses a special embossing roller to calender the glass ribbon to form an embossed surface with a pointed cone-shaped embossed groove, thereby improving the transmittance of the ultra-white embossed glass without reducing the iron content; at the same time, since no additional iron removal equipment and raw materials are required, the technical solution also shows a significant cost advantage.

[0015] Preferably, the raw material in S1 is a combination of one or more of refined silica sand, calcite and dolomite; the iron removal method in S1 is magnetic separation or panning; the crushing method in S1 includes crushing, mixing, ball milling and screening, so that the iron content (in terms of Fe2O3) in the raw material powder is between 0 and 100 ppm.

[0016] Preferably, the smelting temperature in S2 is 1500-1600° C., and after being completely melted, the temperature is kept for 20-30 minutes.

[0017] Preferably, the temperature of the working part of the calendering molding in S4 is controlled at 1000-1160° C., and the calendering speed is 140-200 m / h.

[0018] Preferably, the embossing roller in S4 is made of alloy steel or stainless steel, the roller surface of the embossing roller is evenly provided with pointed cone-shaped embossing blocks, and the roller surface of the embossing roller is polished and then sprayed with a wear-resistant coating.

[0019] Preferably, the temperature of the resistance furnace in S5 is set to 400-550° C., and the annealing time is 10-30 minutes.

[0020] Preferably, a light scattering inhibitor is added before the pulverization in S1; the light scattering inhibitor is optical grade titanium oxide and zirconium oxide.

[0021] Preferably, before the cooling treatment in S5, an anti-reflection film layer is sprayed on the embossed surface of the semi-finished glass.

[0022] Preferably, the anti-reflection film layer is formed by spraying silica sol.

[0023] Preferably, before S3, a plurality of optical fibers are vertically placed in the tin bath, the optical fibers are evenly distributed in the tin bath, and after the glass ribbon is formed, a cutting device is used to cut off one end of the optical fiber protruding from the surface of the glass ribbon; after S4, one of the embossed grooves corresponds to one optical fiber, the optical fiber is attached to the groove wall of the embossed groove, and the optical fiber passes through the glass ribbon.

[0024] The present invention has the following beneficial effects:

[0025] First, steps S1 to S2 involve iron removal, crushing and smelting of raw materials, which are conventional steps in glass production and are mainly used to ensure the purity of glass and the quality of molten glass after melting; although iron removal can reduce the iron content in glass and thus improve light transmittance; next, tin bath forming in step S3 is a standard process in glass production, which spreads the glass liquid to form a glass ribbon and has no direct effect on light transmittance; embossing forming in step S4 uses a special embossing roller to roll the glass ribbon to form a single velvet surface and an embossed surface composed of multiple conical embossing grooves; this step has a potential impact on light transmittance; the conical embossing groove design can reduce the reflection of light on the glass surface and increase the transmission of light inside the glass, thereby improving light transmittance; this design does not rely on reducing the iron content, but achieves the improvement of light transmittance by changing the microstructure of the glass surface; Finally, the annealing and cooling in step S5 are necessary steps in glass production, which are used to eliminate residual stress in the glass and improve the stability of the glass; these steps have little effect on the transmittance; from a cost perspective, although the special embossing roller may require a certain initial investment, once it is put into production, its cost will be spread over a large number of products, thereby reducing the cost of a single product; in addition, since there is no need to increase the transmittance by reducing the iron content, the cost of iron removal equipment and raw materials can be saved, further improving the overall cost advantage; in summary, the technical solution uses a special embossing roller to calender the glass ribbon to form an embossed surface with a pointed cone-shaped embossing groove, thereby improving the transmittance of the ultra-white embossed glass without reducing the iron content; at the same time, since no additional iron removal equipment and raw materials are required, the technical solution also shows a significant cost advantage. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0027] Figure 1 This is a flow chart of the first embodiment of the present invention.

[0028] Figure 2 This is a cross-sectional view of a glass product according to a first embodiment of the present invention.

[0029] Figure 3 This is a cross-sectional view of an embossing roller according to a first embodiment of the present invention.

[0030] Figure 4 It is a plan cross-sectional view of glass according to a second embodiment of the present invention.

[0031] In the figure: 1. finished glass product; 101. single velvet surface; 102. embossed surface; 103. anti-reflection film layer; 2. embossing roller; 201. embossing block; 3. optical fiber. DETAILED DESCRIPTION

[0032] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0033] The first embodiment is a method for producing single-sided ultra-clear patterned glass. Figure 1-2 As shown, the process comprises the following steps: iron removal and crushing: the raw material is subjected to iron removal and crushing treatment to obtain raw material powder; smelting: the raw material powder is added into a glass melting furnace for smelting, and a clarifier is added to obtain glass liquid; tin bath molding: the glass liquid flows into the tin bath through a flow channel, and the glass liquid is spread out to form a glass ribbon; embossing molding: a special embossing roller 2 is used to roll the glass ribbon to form a single velvet surface 101 on one side of the glass ribbon, and an embossed surface 102 is formed on the other side of the glass ribbon, the embossed surface 102 is composed of a plurality of pointed cone-shaped embossed grooves, and the plurality of embossed grooves are evenly distributed on the embossed surface 102 to obtain a semi-finished glass; annealing and cooling: after rolling and molding, the semi-finished glass is immediately transferred to a resistance furnace for annealing treatment. After the annealing is completed, the semi-finished glass is cooled by natural cooling to obtain a glass product 1.

[0034] like Figure 1-2As shown, first, steps S1 to S2 involve iron removal, crushing and smelting of raw materials, which are conventional steps in glass production and are mainly used to ensure the purity of glass and the quality of molten glass after melting; although iron removal treatment can reduce the iron content in glass and thus improve transmittance; next, the tin bath forming in step S3 is a standard process in glass production, which spreads the glass liquid to form a glass ribbon and has no direct effect on transmittance; the embossing forming in step S4 uses a special embossing roller 2 to roll the glass ribbon to form a single velvet surface 101 and an embossed surface 102 composed of a plurality of pointed cone-shaped embossed grooves; this step has a potential effect on transmittance; the pointed cone-shaped embossing groove design can reduce the reflection of light on the glass surface and increase the transmission of light inside the glass, thereby improving transmittance; this design does not rely on reducing the iron content, but achieves transmittance by changing the microstructure of the glass surface. improvement; finally, the annealing and cooling in step S5 are necessary steps in glass production, which are used to eliminate residual stress in the glass and improve the stability of the glass; these steps have little effect on the transmittance; from a cost perspective, although the special embossing roller 2 may require a certain initial investment, once it is put into production, its cost will be spread over a large number of products, thereby reducing the cost of a single product; in addition, since there is no need to increase the transmittance by reducing the iron content, the cost of iron removal equipment and raw materials can be saved, further improving the overall cost advantage; in summary, the technical solution uses a special embossing roller 2 to calender the glass ribbon to form an embossed surface 102 with a conical embossing groove, thereby improving the transmittance of the ultra-white embossed glass without reducing the iron content; at the same time, since no additional iron removal equipment and raw materials are required, the technical solution also shows significant cost advantages.

[0035] One or more combinations of refined silica sand, calcite and dolomite are selected as raw materials because these raw materials are the main components of glass production. Refined silica sand (SiO2) is the main component of glass, while calcite (CaCO3) and dolomite (mainly CaCO3 and MgCO3) provide the necessary calcium and magnesium ions for adjusting the composition and properties of glass. Magnetic separation or elutriation is used to remove iron impurities in the raw materials. Magnetic separation uses the magnetism of iron to separate iron-containing impurities through a magnetic field; elutriation separates iron impurities with a larger specific gravity from the raw materials through the flushing of water flow and gravity. Both methods can effectively reduce the iron content in the raw materials, because iron impurities affect the transparency and color of the glass. Through the steps of crushing, mixing, ball milling and sieving, the raw materials are processed into raw material powders with uniform fineness and reasonable particle size distribution. The crushing and ball milling process can reduce the particle size of the raw materials and increase their specific surface area, which is beneficial to the subsequent smelting process; the mixing process ensures that the components in the raw materials are evenly distributed; sieving removes oversized or undersized particles to ensure that the particle size distribution of the raw material powder meets the requirements.

[0036] After fine pulverization, the particle size distribution of the raw material powder is more reasonable, which is conducive to the uniform mixing and reaction of the components during the smelting process, thereby improving the physical and chemical properties of the glass, such as strength and heat resistance. The pretreatment process of the raw materials (iron removal and pulverization) can significantly improve the efficiency and stability of the subsequent smelting process and reduce the problems that may occur during the smelting process, such as agglomeration and blockage. By optimizing the selection of raw materials and the pretreatment process, the energy consumption and waste emissions in the production process can be reduced, which meets the requirements of environmental protection and sustainable development.

[0037] The melting temperature is set at 1500-1600℃ based on the physical and chemical properties of the raw materials and the desired glass characteristics. This temperature range is sufficient to completely melt raw materials such as refined silica sand, calcite and dolomite and form a uniform glass liquid. Too low a melting temperature may result in incomplete melting of the raw materials, while too high a temperature may cause certain components in the glass liquid to volatilize or react unnecessarily, affecting the quality and performance of the glass. After the raw materials are completely melted, the temperature is kept at 20-30 minutes to ensure that the gas and impurities in the glass liquid have enough time to discharge and react. At high temperatures, the bubbles and dissolved gases in the glass liquid gradually diffuse to the surface and are discharged, while some impurities may react with the added clarifier and precipitate. This period of heat preservation helps to further improve the purity and uniformity of the glass liquid.

[0038] When the embossing roller 2 is embossing, the working temperature is controlled within the range of 1000-1160°C. This temperature range is selected based on the viscosity and fluidity of the glass liquid. Within this temperature range, the glass liquid has sufficient fluidity to be rolled into the desired shape by the embossing roller 2, but will not be overly softened due to excessive temperature, resulting in unstable shape or reduced surface quality of the rolled glass ribbon. The rolling speed is controlled within the range of 140-200m / h. This speed is selected based on the efficiency of rolling and the quality of the glass ribbon. An appropriate rolling speed can ensure that the glass ribbon is uniformly and stably formed under the action of the embossing roller 2, and can control the formation of the velvet structure. Too fast a rolling speed may result in the glass ribbon not being fully rolled and the velvet structure being uneven; while too slow a speed may reduce production efficiency.

[0039] like Figure 3As shown, the embossing roller 2 is made of alloy steel or stainless steel, both of which have good mechanical properties, corrosion resistance and wear resistance. Alloy steel has high strength and hardness and can withstand greater pressure and friction; stainless steel has excellent corrosion resistance and can operate stably for a long time in harsh environments such as high temperature and humidity. The roller surface of the embossing roller 2 is evenly provided with pointed cone-shaped embossing blocks 201, which will form corresponding indentations on the glass ribbon during the rolling process, thereby forming the required velvet structure. The pointed cone-shaped embossing blocks 201 can produce clear and uniform indentations to ensure the uniformity and fineness of the velvet structure. The roller surface of the embossing roller 2 is first polished to remove the roughness and unevenness of the surface and improve the finish and smoothness of the roller surface. Then, a wear-resistant coating is sprayed on the polished roller surface to improve the wear resistance and service life of the roller surface. The wear-resistant coating can effectively resist the friction and wear generated by the glass liquid during the rolling process and maintain the flatness and clarity of the roller surface.

[0040] The resistance furnace temperature is set to 400-550℃, and this temperature range is selected based on the annealing characteristics of the glass. Within this temperature range, the glass can gradually release internal stress without causing significant changes in the glass structure or surface damage due to excessive temperature. The appropriate annealing temperature helps ensure that the glass maintains stable performance during the annealing process. The annealing time is set to 10-30 minutes, and the choice of this time depends on the thickness and size of the glass and the required annealing effect. Sufficient annealing time can ensure that the internal stress of the glass is fully released and improve the mechanical strength and thermal stability of the glass. Too short annealing time may lead to incomplete stress release, while too long annealing time may increase energy consumption and production costs.

[0041] Light scattering is the phenomenon that when light propagates in a medium, the light deviates from its original propagation direction due to the inhomogeneity of the medium. In the glass manufacturing process, impurities and bubbles in the raw materials can cause light scattering and reduce the light transmittance of the glass. Light scattering inhibitors such as optical grade titanium oxide and zirconium oxide have a refractive index similar to that of the glass matrix, which can reduce the scattering of light inside the glass and increase the light transmittance of the glass. Adding light scattering inhibitors before the crushing process can ensure that the inhibitors are fully mixed with the raw materials, so that they are evenly distributed in the glass during the subsequent melting and molding processes. This can more effectively reduce light scattering and improve the optical properties of the glass.

[0042] Before the cooling process, the embossed surface 102 of the semi-finished glass is sprayed with an anti-reflection film layer 103. By spraying the anti-reflection film layer 103 composed of silica sol, the reflection loss of light on the glass surface can be significantly reduced, thereby improving the light transmittance of the glass. This helps to improve the visual effect of the glass product, making it brighter and clearer. The anti-reflection film layer 103 is sprayed with silica sol.

[0043] Since silica sol has excellent weather resistance and adhesion, the anti-reflection film layer 103 sprayed on the glass surface has good durability. Even after long-term use and exposure to harsh environments, the film layer can maintain its anti-reflection performance, ensuring the long-term stability and reliability of the glass product.

[0044] In the second embodiment, in the proposed technical solution, the optical fiber 3 is introduced into the production process of the glass ribbon, especially in the application stage in the tin bath and the embossing groove. First, a plurality of optical fibers 3 are placed vertically in the tin bath, and these optical fibers 3 are evenly distributed. When the glass ribbon is formed in the tin bath, a portion of the optical fiber 3 will be higher than the surface of the glass ribbon. Subsequently, the optical fiber 3 that is higher than the surface of the glass ribbon is cut off using a cutting device. When the glass ribbon passes through the embossing groove, each optical fiber 3 corresponds to an embossing groove and is attached to the groove wall of the embossing groove. Since the optical fibers 3 have excellent light-guiding properties, they can pass through the glass ribbon without being hindered by the internal structure of the glass ribbon. By introducing the optical fibers 3, new functions can be added to the glass ribbon. For example, the optical fibers 3 can transmit light, so that the glass ribbon has the function of guiding or emitting light, which is suitable for occasions requiring special lighting effects.

[0045] The above are only specific embodiments of the present invention, but the technical features of the present invention are not limited thereto. Any simple changes, equivalent replacements or modifications made based on the present invention to solve basically the same technical problems and achieve basically the same technical effects are all within the scope of protection of the present invention.

Claims

1. A method for producing single-sided ultra-clear patterned glass, characterized in that: The following steps are involved: S1. Deironing and pulverizing: deironing and pulverizing the raw materials to obtain raw material powder; S2, melting: adding the raw material powder into a glass melting furnace for melting, and adding a clarifier to obtain molten glass; S3, tin bath forming: the molten glass flows into the tin bath through the flow channel, and the molten glass is spread out to form a glass ribbon; S4, embossing molding: using a special embossing roller (2) to roll the glass ribbon, forming a single velvet surface (101) on one side of the glass ribbon and an embossed surface (102) on the other side of the glass ribbon, wherein the embossed surface (102) is composed of a plurality of pointed cone-shaped embossed grooves, and the plurality of embossed grooves are evenly distributed on the embossed surface (102), thereby obtaining a semi-finished glass; S5, annealing and cooling: After rolling and forming, the semi-finished glass is immediately transferred to a resistance furnace for annealing. After annealing, the semi-finished glass is cooled by natural cooling to obtain a finished glass product (1).

2. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: The raw material in S1 is a combination of one or more of refined silica sand, calcite and dolomite; the iron removal method in S1 is magnetic separation or elutriation; the crushing method in S1 includes crushing, mixing, ball milling and screening, so that the iron content (in terms of Fe2O3) in the raw material powder is between 0 and 100 ppm.

3. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: The smelting temperature in S2 is 1500-1600° C. and after being completely melted, the smelting temperature is kept for 20-30 minutes.

4. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: The temperature of the calendering working part in S4 is controlled at 1000-1160° C., and the calendering speed is 140-200 m / h.

5. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: The embossing roller (2) in S4 is made of alloy steel or stainless steel, and the roller surface of the embossing roller (2) is evenly provided with pointed cone-shaped embossing blocks (201). The roller surface of the embossing roller (2) is polished and then sprayed with a wear-resistant coating.

6. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: In the S5, the temperature of the resistance furnace is set to 400-550° C., and the annealing time is 10-30 minutes.

7. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: In the S1, a light scattering inhibitor is added before the pulverization process; the light scattering inhibitor is optical grade titanium oxide and zirconium oxide.

8. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: Before the cooling process in S5, an anti-reflection film layer (103) is sprayed on the embossed surface (102) of the semi-finished glass.

9. The method for producing single-faced ultra-clear patterned glass according to claim 8, characterized in that: The anti-reflection film layer (103) is formed by spraying silica sol.

10. The method for producing single-faced ultra-clear patterned glass according to claim 1, characterized in that: Before S3, a plurality of optical fibers (3) are vertically placed in the tin bath, and the optical fibers (3) are evenly distributed in the tin bath. After the glass ribbon is formed, a cutting device is used to cut off one end of the optical fiber (3) that is higher than the surface of the glass ribbon. After S4, one embossed groove corresponds to one optical fiber (3), and the optical fiber (3) is attached to the groove wall of the embossed groove, and the optical fiber (3) passes through the glass ribbon.

Images