Solar panel with mesh-shaped colored coating and production method thereof, and colored solar photovoltaic module

Abstract

The present invention discloses a solar panel with a mesh-shaped color coating and a production method thereof. The production method comprises the following steps: (1) designing and manufacturing a screen plate with a dot array photosensitive pattern; (2) printing an LED-cured color coating on a transparent substrate through the screen plate to form a mesh-shaped color coating with light-transmitting holes; (3) irradiating the coating with LED ultraviolet light to preliminarily cure the coating; (4) heating and post-curing the preliminarily cured coating to form a solar panel with a mesh-shaped color coating; in terms of the mass percentage of the raw materials, the LED-cured color coating comprises: 45-65% LED photosensitive polymer; 12-27% photoactive diluent; 1-5% photosensitizer; 1-2% adhesion promoter; 3-15% pigment; 0.5-2% ultraviolet light absorber; and 0.01-3% leveling agent. The present invention also discloses the application of the solar panel in a color solar photovoltaic module. The present invention creatively solves the contradiction that the aesthetics and light transmittance of solar products cannot be unified.

Description

Technical Field

[0001] The invention relates to the field of solar photovoltaics, and in particular to a solar panel with a sieve-shaped colored coating, a production method thereof, and a colored solar photovoltaic component. Background Art

[0002] If photovoltaics are to enter cities, aesthetics must come first. If solar energy is to enter cities, it must meet the public's aesthetic needs. Aesthetics is a prerequisite. No matter how efficient solar energy is, it cannot be promoted in large quantities in cities if it does not change its original appearance of being black, ugly and stupid. Colored solar energy is a rigid demand for urban carbon neutrality.

[0003] Since solar cells are dark blue or black, solar modules are also dark in color. How to make blue-black photovoltaic modules present bright colors without reducing light transmittance and affecting photoelectric conversion efficiency has become a technical obstacle to the development of solar energy. Printing a layer of colored coating on the surface of photovoltaic glass to cover the black bottom is an effective method, but it also reduces light transmittance and affects the power generation efficiency of solar products to varying degrees.

[0004] The Chinese patent document with application number CN202110281087.4 discloses a solar panel with a honeycomb color coating, a production method thereof, and a color solar photovoltaic module, comprising the following steps: applying a UV color coating on a transparent substrate, preheating the substrate, irradiating the UV color coating with ultraviolet light for preliminary curing after preheating, and obliquely punching the UV color coating after preliminary curing with a laser beam to form light-transmitting holes, so that the UV color coating forms a honeycomb structure; heating and curing the perforated coating to form a solar panel with a honeycomb color coating;

[0005] The above laser etching and drilling process has a high degree of automation and improves the light transmittance, but the equipment investment is large and the production cost is high, which is not conducive to the large-scale promotion of color solar energy products.

[0006] The Chinese patent document with application number CN202110281099.7 discloses a method for producing a high-transmittance color solar panel and a color solar photovoltaic module, comprising the following steps: applying a UV-curable color coating on a transparent substrate to form a UV-curable color coating; pressing a template with a protrusion array to the UV-curable color coating, and mechanically embossing the UV-curable color coating; irradiating the UV-curable color coating with ultraviolet light at the same time to dry and solidify the UV-curable color coating; removing the template, forming a light-transmitting hole complementary to the protrusion array on the color coating; post-curing the demoulding color coating to obtain the high-transmittance color solar panel. The mechanical embossing process does improve the light transmittance of the coating, but the production of the embossed template is expensive, the cost is high, and the process is complicated.

[0007] Therefore, it is necessary to develop high-efficiency, low-cost, low-investment, and high-transmittance colored photovoltaic products to facilitate mass production and application. Summary of the invention

[0008] The present invention provides a method for producing a solar panel with a sieve-shaped color coating. LED color ink is directly leak-printed on a transparent substrate using a silk screen to form a highly light-transmitting solar panel with a sieve-shaped color coating. The light transmittance of the solar panel is significantly improved without affecting the color and aesthetics.

[0009] The technical solution of the present invention is as follows:

[0010] A method for producing a solar panel having a mesh-shaped colored coating comprises the following steps:

[0011] (1) Design and manufacture a screen plate with a dot array photosensitive pattern;

[0012] (2) printing the LED-cured color coating on a transparent substrate through a screen plate to form a mesh-shaped color coating having light-transmitting through holes; the pattern of the mesh-shaped color coating is complementary to the dot array photosensitive pattern on the screen plate;

[0013] (3) Irradiating the coating with LED ultraviolet light to initially cure the coating and keep the sieve-like pattern from deforming;

[0014] (4) heating and curing the preliminarily cured coating to form a solar panel with a mesh-shaped colored coating;

[0015] Calculated by the mass percentage of raw materials, the LED curing color coating comprises: 45-65% LED photosensitive polymer; 12-27% photoactive diluent; 1-5% photosensitizer; 1-2% adhesion promoter; 3-15% pigment; 0.5-2% ultraviolet light absorber; and 0.01-3% leveling agent.

[0016] LED photosensitive polymer is one of the main components of the coating, which determines the adhesion of the cured film to the substrate, surface hardness and other properties. High-functionality fluorine-containing photosensitive resin can increase the surface hardness of the coating and improve the weather resistance of the coating. Low-energy curing photosensitive resin accelerates the LED light curing speed.

[0017] The LED photosensitive polymer is at least one of modified polyester acrylic resin and polyurethane acrylic resin; the functionality is 2-6.

[0018] The LED photosensitive polymer has good yellowing resistance, low LED light curing energy and fast curing speed, which ensures that the sieve-shaped color coating has excellent adhesion to the substrate, weather resistance, salt spray resistance, and high and low temperature resistance.

[0019] Preferably, the LED photosensitive polymer is at least one of the following polymers:

[0020] Guangzhou Wuxing Material Technology Co., Ltd.'s low-energy curing, yellowing-resistant modified epoxy acrylate G5100X, G5200X, and G5292 have a functionality of 2; Zhongshan Qianyou Chemical Materials Co., Ltd.'s special modified epoxy resins UV1510C and UV1510A have a functionality of 2; Changxing Special Materials Co., Ltd.'s fluorine-modified polyurethane acrylate 61998 has a functionality of 15; Shanghai Baorun Chemical Co., Ltd.'s fluorine-modified polyurethane acrylate resin 7468 has a functionality of 4; Zhaoqing Baojun Chemical Co., Ltd.'s LED light-curing resin LED-UV3 with a functionality of 4, and LED light-curing resin LED-UV-6 with a functionality of 6.

[0021] The photoactive diluent is at least one of the low-viscosity acrylate monomers, and the functionality is 1 to 6. The low-viscosity photoactive diluent is mainly used to adjust the viscosity of the LED-cured color coating and the properties of the coating cured film.

[0022] Preferably, the photoactive diluent is at least one of isobornyl acrylate (IBOA), 1,6-hexanediol diacrylate (HDDA), ethoxylated 1,6-hexanediol diacrylate, acryloyl morpholine (ACMO), methacrylate oxetane, 3,3,5-trimethylcyclohexyl acrylate, tricyclohexanedimethanol diacrylate (EM2204) and LED-43 monomer of Guangzhou Boxing Technology Co., Ltd.

[0023] The photosensitizer can be selected from conventional commercially available photosensitizers. Preferably, the photosensitizer is at least one of 1-hydroxycyclohexyl benzophenone (184), 2-hydroxy-2-methyl-1-phenyl-1-propanone (1173), 2,4,6-trimethylbenzoyl-diphenylphosphine oxide (TPO), and phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide (819).

[0024] The adhesion promoter is a phosphate monomer with a double bond; further preferably, the adhesion promoter is at least one of 9107 and 9108 produced by Guangzhou Runao Chemical Materials Co., Ltd. and PM-2 produced by Nippon Kayaku Co., Ltd.

[0025] The leveling agent is an organic silicon auxiliary agent with a leveling function. Preferably, the leveling agent is at least one of Digo 2700 and Digo 2650 of Digo Company, BYK-354, BYK-3500 and BYK-3510 of BYK Company.

[0026] The pigment is a weather-resistant pigment, which can be an inorganic pigment or an organic pigment; it can be transparent, such as colored pearl powder, colored rock flakes, etc.; it can also be opaque, such as metallic pigment flake aluminum powder, copper powder, inorganic pigment such as nano transparent iron oxide red, iron yellow, etc.

[0027] The transparent substrate is glass or a transparent plastic film. When the substrate is a transparent plastic film, the prepared solar panel can be used to prepare a flexible color solar photovoltaic module.

[0028] In step (1), the screen mesh number of the screen plate is 100-300 meshes, and the wire diameter is 30-100 microns. Preferably, the screen mesh number is 180-300 meshes, and the wire diameter is 35-60 microns.

[0029] The pattern of the sieve-shaped color coating and the dot-array photosensitive pattern on the screen have a yin-yang relationship with each other.

[0030] The light-transmitting holes of the sieve-shaped color coating can be in shapes such as circular, linear, or square, which can maximize light transmission and improve power generation efficiency without affecting the appearance and color of the product.

[0031] The sieve-shaped light-transmitting holes printed on the transparent substrate allow sunlight to pass through the light-transmitting holes and directly illuminate the solar cells under the coating without changing the aesthetics of the product, significantly improving the light transmittance and photoelectric conversion efficiency of the photovoltaic module.

[0032] By adjusting the aperture and density of the light-transmitting holes in the colored coating, that is, controlling the ratio of the sieve area to the total coating area, the transmittance deviation between coatings of different colors can be balanced, so that the transmittance of coatings of different colors remains similar. Under the premise of ensuring the transmittance, the color selection range of solar products is broadened.

[0033] Preferably, the diameter of the light-transmitting through holes is 0.1-5 mm; the total area of ​​the light-transmitting through holes accounts for 3-45% of the total area of ​​the sieve-shaped color coating.

[0034] The larger the diameter of the light-transmitting hole, the more holes there are, and the higher the light transmittance of the printed coating, but it will affect the appearance of the solar product; the smaller the hole diameter, the fewer holes there are, and the smaller the proportion of light-transmitting area of ​​the coating. Although it does not affect the appearance and color, the light transmittance is lower. When the hole diameter is too small, printing is more difficult. Usually, the minimum hole diameter for screen printing is 0.1 mm. The ideal state is to increase the number of screen holes, reduce the hole diameter, and control the proportion of light-transmitting area.

[0035] Further preferably, the diameter of the light-transmitting through holes is 0.2-1.5 mm; the total area of ​​the light-transmitting through holes accounts for 5-20% of the total area of ​​the sieve-shaped color coating.

[0036] This technical solution does not affect the color and appearance of the product, and can significantly improve the light transmittance of the coating.

[0037] The thickness of the mesh-shaped colored coating is 8-50 microns, preferably 15-30 microns.

[0038] In step (3), LED ultraviolet light is used to irradiate the printed mesh pattern coating, causing the material in the liquid coating to undergo a photocuring reaction such as radiation polymerization or radiation cross-linking, so that the color coating can be quickly dried and cured, especially the edges of the smaller mesh holes will not seep or deform.

[0039] When ordinary UV light irradiates the color coating in the air, it will produce ozone, pollute the environment, consume a lot of energy, and cannot be used for heat-sensitive plastic films. If the ultraviolet light energy is too small, the coating will not be completely cured, the surface hardness will be low, and the comprehensive performance such as water resistance will be poor; if the light energy is too large, the cured film will turn yellow, thereby affecting the transmittance and photoelectric conversion efficiency.

[0040] Preferably, the wavelength of the irradiated LED ultraviolet light is 365-405 nm; preferably 365 nm, 385 nm, 395 nm or 405 nm; most preferably 395 nm.

[0041] Different coating thicknesses and colors require different LED light energies for curing coatings. The energy of LED UV light irradiation is 150-1100 mJ / cm2.

[0042] In step (4), the post-curing by heating refers to IR heating of the light-cured color coating. Both the IR heating temperature and time will affect the comprehensive performance of the color coating. When the temperature is lower than 80°C, the performance improvement is not obvious, while when the temperature is higher than 200°C, the coating will turn yellow and age.

[0043] Preferably, the post-heating curing is IR heating curing; the temperature is 80-200° C.; and the time is 3-20 min.

[0044] More preferably, the temperature is 120-180° C. and the time is 3-10 min.

[0045] Based on the same inventive concept, the present invention also provides a solar panel with a sieve-shaped colored coating produced by the above production method.

[0046] Based on the same inventive concept, the present invention also provides a colored solar photovoltaic assembly, including the above-mentioned solar panel with the sieve-shaped colored coating.

[0047] Compared with the prior art, the present invention has the following beneficial effects:

[0048] (1) The present invention uses a screen plate to directly print the LED-cured color coating on a transparent substrate, forming a light-transmitting mesh pattern complementary to the screen plate, so that sunlight can penetrate the coating to the maximum extent and directly illuminate the surface of the solar cell. The color and aesthetics of the produced color solar panels are not affected, and the light transmittance is significantly improved, creatively solving the contradiction between the aesthetics and light transmittance of solar products;

[0049] (2) The production method of the present invention has simple process, small investment, low cost, high yield rate, and is convenient for mass production;

[0050] (3) By adjusting the aperture and density of the light-transmitting holes in the printed pattern, that is, controlling the ratio of the mesh area to the total coating area, the transmittance deviation between coatings of different colors can be balanced, so that the transmittance of coatings of different colors remains similar, which broadens the color selection range of solar products and effectively reduces the hot spot effect of photovoltaic modules and reduces the probability of burning photovoltaic modules;

[0051] (4) The LED-cured color coating of the present invention does not contain volatile VOCs, does not emit VOCs during the production process, and LED ultraviolet light does not generate ozone, which has the advantages of being environmentally friendly, energy-saving, and highly efficient. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 It is a schematic diagram of the screen photosensitive adhesive pattern;

[0053] Figure 2 Schematic diagram of a coating with a mesh structure obtained by screen printing;

[0054] Figure 3 A schematic cross-sectional view of a solar panel with a mesh-like colored coating. DETAILED DESCRIPTION

[0055] Example 1

[0056] Mesh-shaped gold LED coating formula (raw material mass percentage):

[0057]

[0058] The components in the above formula are stirred evenly, and the above gold coating is printed on the glass surface using a 200-mesh dot screen to obtain a 21-micron sieve color coating with a light-transmitting aperture of 1 mm and a light-transmitting area of ​​10%; the LED light curing wavelength is 395 nm, and the irradiation energy is 700 mJ / cm2; the light-cured glass is heated at 160°C for 10 minutes to obtain a sieve-shaped gold solar glass panel.

[0059] When viewed from a distance, it appears to be uniformly colored golden glass; when viewed up close, the surface is dotted with light-transmitting sieve holes. Physical and chemical indicators such as light transmittance were measured, as shown in Appendix 1.

[0060] Example 2

[0061] Mesh-shaped silver-white LED coating formula (raw material mass percentage):

[0062]

[0063] The components in the above formula are stirred evenly, and the above gold coating is printed on the glass surface using a 200-mesh dot screen to obtain a 17-micron sieve color coating with a light-transmitting aperture of 1 mm and a light-transmitting area of ​​17%; the LED light curing wavelength is 395 nm, and the irradiation energy is 500 mJ / cm2; the light-cured glass is heated at 170°C for 8 minutes to obtain a sieve-shaped silver-white solar glass panel.

[0064] When viewed from a distance, it appears to be silver-white glass with uniform color. When viewed up close, the surface is dotted with light-transmitting sieve holes. The physical and chemical indicators such as light transmittance were measured and are shown in Table 1.

[0065] Example 3

[0066] Mesh-shaped red LED coating formula (raw material mass percentage):

[0067]

[0068] The components in the above formula are mixed evenly, and the above colored coating is printed on the surface of photovoltaic glass using a 200-mesh dot screen to obtain a red sieve coating with a thickness of 22 microns, a light-transmitting aperture of 1 mm, and a light-transmitting area of ​​25%; the LED light curing wavelength is 395 nm, and the irradiation energy is 1000 mJ / cm2; the light-cured glass is heated at 180°C for 5 minutes to obtain a sieve-shaped red solar glass panel.

[0069] When viewed from a distance, it appears to be red glass with uniform color. When viewed up close, there are light-transmitting sieve holes distributed on the surface. The physical and chemical indicators such as light transmittance were measured, see Appendix 1.

[0070] Comparative Example 1

[0071] Formula of non-porous golden LED coating (mass percentage of raw materials):

[0072]

[0073] The components of the above formula were mixed evenly, and the above colored coating was printed on the surface of the photovoltaic glass using a 200-mesh screen to obtain a colored coating with a thickness of 21 microns; preheated at 50°C for 30 seconds to allow the coating to fully defoam and level; LED light curing with an irradiation energy of 800 mJ / cm2; the LED coating was placed at room temperature for 18 hours to dry and cure naturally without drilling, thus obtaining a non-porous golden solar glass panel, and the transmittance and other physical and chemical indicators were measured, see Appendix 1.

[0074] Comparative Example 2

[0075] Non-porous silver-white LED coating formula (raw material mass percentage):

[0076]

[0077]

[0078] The components in the above formula were stirred evenly, and the above coating was printed on the glass surface using a 200-mesh blank screen plate to obtain a 17-micron-thick, non-porous silver-white coating. The LED light curing wavelength was 395nm, and the irradiation energy was 500 millijoules / square centimeter. The light-cured glass was heated at 170°C for 8 minutes to obtain a solid silver-white solar glass panel. The transmittance and other physical and chemical indicators were measured, see Appendix 1.

[0079] Comparative Example 3

[0080] Non-porous red LED coating formula (raw material mass percentage):

[0081]

[0082] The components in the above formula were stirred evenly, and the above colored coating was printed on the surface of photovoltaic glass using a 200-mesh blank screen plate to obtain a 22-micron thick red non-porous coating, with an LED light curing wavelength of 395nm and an irradiation energy of 1000 mJ / cm2; the light-cured glass was heated at 180°C for 5 minutes to obtain a full-plate red solar glass panel. Physical and chemical indicators such as light transmittance were measured, as shown in Table 1.

[0083] Figure 1 is the screen photosensitive resin pattern used in the above embodiments, Figure 2 The schematic diagram of the mesh-shaped color coating obtained by screen printing in the above embodiment. The pattern of the screen-printed photosensitive resin and the pattern of the mesh-shaped color coating are complementary.

[0084] Figure 3 Schematic diagram of the cross-sectional structure of a solar glass panel with a sieve-shaped color coating. It can be seen that the sieve-shaped color coating has screen-printed light-transmitting holes.

[0085] The performance of the LED coatings of Examples 1-3 and Comparative Examples 1-3 was tested, and the test results are shown in Table 1.

[0086] Table 1

[0087]

[0088] It can be seen from Table 1 that the light transmittance of the coating with mesh is significantly improved without changing the color and aesthetics of the product.

[0089] The embodiments described above provide a detailed description of the technical solutions and beneficial effects of the present invention. It should be understood that the above are only specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, supplements and equivalent substitutions made within the scope of the principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for producing a solar panel having a mesh-shaped color coating, characterized in that: The following steps are involved: (1) Designing and manufacturing a screen plate with a dot array photosensitive pattern; the screen plate has a mesh count of 100-300 meshes and a wire diameter of 30-100 microns; (2) The LED-cured color coating is screen-printed on a transparent substrate through a silk screen to form a mesh-shaped color coating having light-transmitting through holes; the pattern of the mesh-shaped color coating is complementary to the dot-shaped array photosensitive pattern on the silk screen; the diameter of the light-transmitting through holes is 0.1-5 mm; and the total area of ​​the light-transmitting through holes accounts for 3-45% of the total area of ​​the mesh-shaped color coating; (3) Irradiate the coating with LED ultraviolet light to initially solidify the coating and keep the sieve-like pattern from deforming; (4) heating and curing the preliminarily cured coating to form a solar panel with a mesh-shaped colored coating; Calculated by the mass percentage of raw materials, the LED curing color coating comprises: 45-65% LED photosensitive polymer; 12-27% photoactive diluent; 1-5% photosensitizer; 1-2% adhesion promoter; Pigment 3-15%; UV absorber 0.5-2%; Leveling agent 0.01-3%; The LED photosensitive polymer is at least one of modified polyester acrylic resin and polyurethane acrylic resin; the functionality is 2-6.

2. The method for producing a solar panel having a mesh-shaped color coating according to claim 1, characterized in that: The photoactive diluent is at least one of low-viscosity acrylic ester monomers with a functionality of 1-6.

3. The method for producing a solar panel with a mesh-shaped color coating according to claim 1, characterized in that: The thickness of the mesh-shaped colored coating is 8-50 microns.

4. The method for producing a solar panel with a mesh-shaped color coating according to claim 3, characterized in that: The diameter of the light-transmitting through hole is 0.2-1.5 mm; the total area of ​​the light-transmitting through hole accounts for 5-20% of the total area of ​​the sieve-shaped color coating.

5. The method for producing a solar panel with a mesh-shaped color coating according to claim 1, characterized in that: The wavelength of the irradiated LED ultraviolet light is 365-405nm; the irradiation energy is 150-1100 mJ / cm2.

6. The method for producing a solar panel with a mesh-shaped color coating according to claim 1, characterized in that: The post-heating curing is IR heating curing; the temperature is 80-200° C.; and the time is 3-20 minutes.

7. A solar panel with a mesh-shaped colored coating, characterized in that: The product is produced by the production method according to any one of claims 1 to 6.

8. A colored solar photovoltaic module, characterized in that: It comprises a solar panel with a mesh-shaped color coating as described in claim 7.

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