Aluminum frame oxidation nickel-free hole sealing agent for solar cell

Abstract

The invention relates to the technical field of aluminum profile surface treatment, in particular to an aluminum frame oxidation nickel-free hole sealing agent for a solar cell, which is prepared from the following raw materials in parts by weight: 10-50 parts of zinc salt compound; 10-80 parts of a lithium salt compound; 20-50 parts of a calcium salt compound; the cleaning agent also comprises the following raw materials by weight: 12 kg of magnesium acetate, 5 kg of ammonium acetate, 7 kg of sodium acetate, 60 kg of an auxiliary agent, and 650 kg of deionized water. The technology is customized according to different solar application scenes, the performance is excellent in environments such as temperate zones, high humidity and heat, deserts and the like, and stable operation of the photovoltaic module under various weather conditions in the world is ensured.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum profile surface treatment, in particular to an oxidized nickel-free sealing agent for an aluminum frame used in a solar cell. Background Art

[0002] With the rapid development of the solar photovoltaic industry, aluminum profile frames, as key structural components of modules, need to withstand complex outdoor environments for a long time, such as high temperature and humidity, strong ultraviolet radiation, wind and sand erosion, and acid rain corrosion. Traditional nickel-containing sealants are restricted in use due to environmental regulations, and existing nickel-free sealing technologies generally have problems such as insufficient performance, high cost, and lack of system verification. The present invention achieves environmentally friendly, high-performance, and low-cost technological breakthroughs through an innovative zinc-lithium-calcium ternary synergistic component system, combined with targeted solar application scenario process optimization and multi-dimensional verification solutions, and promotes the upgrading of solar aluminum profile surface treatment technology.

[0003] Problems existing in the prior art:

[0004] 1. Industry status quo and pain points:

[0005] Environmental restrictions: Traditional nickel salt sealers contain harmful elements such as Ni and F, and are strictly controlled by regulations such as the EU REACH and China's "Catalogue of Hazardous Chemicals". The cost of wastewater treatment is as high as 200-300 yuan per ton of profile, increasing the compliance burden on enterprises.

[0006] Performance defects: Existing nickel-free sealers (such as magnesium-lithium systems) perform poorly in extreme environments. For example, the sealing efficiency is low in high-temperature and high-humidity environments, and the oxide film corrosion rate is 80% higher than that of the present invention. In strong wind and sand environments, the surface wear is severe and cannot meet the 25-year service life requirement of solar panels.

[0007] High cost: Some high-end nickel-free sealant raw materials rely on imports, with a cost of 15-20 yuan / kg. Although low-end products have lower costs, their performance is unstable, resulting in an increase of about 25% in the maintenance cost of the components throughout their life cycle.

[0008] Lack of verification: Existing technologies lack a systematic verification solution for solar energy application scenarios, making it impossible to accurately evaluate the stability of sealing quality in long-term outdoor environments, making it difficult to ensure the reliable operation of photovoltaic power stations.

[0009] 2. Technology gaps:

[0010] At present, there is no aluminum profile sealing technology that meets the following conditions simultaneously: Environmental protection: completely nickel-free, fluorine-free, and chromium-free, achieving zero pollution emissions; High performance: Excellent corrosion resistance, wear resistance, and weather resistance in a variety of extreme outdoor environments; Low cost: Raw material cost <10 yuan / kg, application cost <400 yuan / ton of profile; Reliability: Through a multi-dimensional verification system, the frame performance of the photovoltaic module is ensured to be stable within the 25-year service life. Summary of the Invention

[0011] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a nickel-free sealing agent for oxidizing aluminum frames for solar cells.

[0012] In order to achieve the above object, the present invention adopts the following technical solutions:

[0013] A nickel-free oxidized sealing agent for an aluminum frame of a solar cell, comprising: 10-50 parts of a zinc salt compound; 10-80 parts of a lithium salt compound; and 20-50 parts of a calcium salt compound;

[0014] The following raw materials are also included by weight: 12kg of magnesium acetate, 5kg of ammonium acetate, 7kg of sodium acetate, 60kg of auxiliary agent, and 650kg of deionized water;

[0015] The solar scene customized process of the aluminum frame oxidation nickel-free sealant is divided into conventional environment process, high humidity and heat / acid rain environment process and desert wind and sand environment process.

[0016] Preferably, the zinc salt compound is a compound of zinc nitrate and zinc lactate.

[0017] Preferably, the lithium salt compound is lithium acetate.

[0018] Preferably, the calcium salt compound is industrial grade calcium phosphate.

[0019] Preferably, in the conventional environmental process, the concentration is 4%, the pH is 4.5, the temperature is 25° C., and the immersion time is 16 minutes to ensure a balance between basic weather resistance and economy.

[0020] Preferably, in the high humidity and heat / acid rain environment process, the concentration is 5%, the temperature is 30° C., the calcium salt ratio is increased to 40%, and the ultrasonic cleaning time is extended to 1 minute.

[0021] Preferably, in the desert sand environment process, the calcium salt accounts for 60% and is mainly calcium phosphate, and the gray suppressant and brightener is increased to 15 parts.

[0022] The beneficial effects of the present invention are:

[0023] 1. Innovative breakthroughs:

[0024] Ternary synergistic mechanism: Difference in ionic radius of zinc-lithium-calcium (Zn 2+ 0.074nm, Li + 0.076nm, Ca 2+ 0.100nm) enables it to cover oxide film micropores of different pore sizes (20-100nm), and the sealing efficiency is increased to 99.2% (traditional nickel-free technology is only 85%);

[0025] Functional additive system: The gray suppressing brightener inhibits the main salt deposition through surface activity, making the surface roughness of the aluminum profile Ra less than 0.8μm, which is better than the national standard requirement (Ra less than 1.6μm).

[0026] 2. Advanced practicality:

[0027] Full-scenario adaptation: Customized processes for different solar application scenarios, excellent performance in temperate, high-humidity and hot, desert and other environments, ensuring stable operation of photovoltaic modules in various climate conditions around the world.

[0028] 3. Environmental protection and economy:

[0029] Zero-pollution production: Completely nickel-free, fluorine-free, and chromium-free, no hazardous chemical storage and wastewater treatment are required, in line with the photovoltaic industry's "net zero emission" goal.

[0030] Cost competitiveness: Through raw material optimization, process simplification and large-scale production, the overall cost is greatly reduced, which significantly improves the market competitiveness of products. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0032] Example 1: A nickel-free sealing agent for aluminum frame oxidation for solar cells, comprising: 10-50 parts of a zinc salt compound; 10-80 parts of a lithium salt compound; 20-50 parts of a calcium salt compound;

[0033] The following raw materials are also included by weight: 12kg of magnesium acetate, 5kg of ammonium acetate, 7kg of sodium acetate, 60kg of auxiliary agent, and 650kg of deionized water;

[0034] The customized solar scene process of aluminum frame oxidation nickel-free sealant is divided into conventional environment process, high humidity and heat / acid rain environment process and desert sand environment process.

[0035] Specifically, the zinc salt compound is a combination of zinc nitrate and zinc lactate. The zinc ions released by zinc nitrate are highly active and react quickly with the oxide film, while zinc lactate's complexing properties regulate the release rate of zinc ions. Together, they form a dense zinc-aluminum oxide composite layer, enhancing corrosion resistance. The raw material cost is only 20 yuan / kg, 40% lower than imported nickel-free sealers.

[0036] Furthermore, the lithium salt compound is preferably lithium acetate, which has an extremely small radius of lithium ions dissociated in a weakly acidic environment, and can effectively reduce the surface tension of the sealing agent to below 30mN / m, thereby increasing the micropore penetration depth by 30%, stabilizing the pH value of the solution, and reducing the dosage by 30%.

[0037] In addition, the calcium salt compound is industrial-grade calcium phosphate, which reacts with the residual acidic substances in the micropores of the oxide film to generate hydroxyapatite-like substances, filling the micropores and increasing the hardness of the oxide film to HV220. The wear-resistant cost is reduced by 70% compared with nanomaterials.

[0038] In this embodiment, the conventional environmental process is suitable for temperate climate zones, with a concentration of 4%, a pH of 4.5, a temperature of 25° C., and an immersion time of 16 minutes to ensure a balance between basic weather resistance and economy.

[0039] Temperate climate zone solar frame sealing:

[0040] 1. Raw material ratio (100kg batch):

[0041] 30kg of zinc salt compound (15kg of zinc nitrate + 15kg of zinc lactate, cost 20 yuan / kg); 50kg of lithium salt compound (30kg of lithium acetate + 20kg of lithium sulfate, cost 25 yuan / kg); 35kg of calcium salt compound (20kg of calcium phosphate + 15kg of calcium nitrate, cost 12 yuan / kg); 12kg of magnesium acetate, 5kg of ammonium acetate, 7kg of sodium acetate (total cost of approximately 212 yuan); 60kg of auxiliary agents (PH stabilizer, surfactant, etc.) (cost 18 yuan / kg); 650kg of deionized water (cost 0.8 yuan / kg); total cost: approximately 847 yuan / 100kg (i.e. 8.47 yuan / kg).

[0042] 2. Process parameters:

[0043] Concentration: 4%; pH value: 4.5; temperature: 25°C; immersion time: 16 minutes.

[0044] 3. Performance test results:

[0045] Salt spray test 1000h: weight loss 3.2mg / dm 2 ;

[0046] The power station has been in operation for 2 years: the power generation efficiency decay rate is 1.2% (2.1% for traditional technology).

[0047] Example 2: Based on Example 1, the following technical solution is also provided:

[0048] In this embodiment, the high humidity and heat / acid rain environment process: the concentration is increased to 5%, the temperature is 30°C, the calcium salt ratio is increased to enhance the acid resistance and moisture resistance; the ultrasonic cleaning time is extended to 1 minute to prevent acid residue in the micropores;

[0049] Solar frame sealing in hot and humid areas:

[0050] 1. Process adjustment:

[0051] Concentration: 5%; Temperature: 30°C; Calcium salt ratio increased to 40%; Ultrasonic cleaning time extended to 1 minute.

[0052] 2. Performance verification:

[0053] Acid rain simulation for 240 hours: weight loss 0.8 mg / dm 2 ;

[0054] Corrosion current in humid environment: 0.12μA / cm 2 (Conventional technology 0.4μA / cm 2 ).

[0055] Example 3: Based on Example 1, the following technical solution is also provided:

[0056] In this embodiment, the process for the desert sandstorm environment is as follows: the proportion of calcium salt is increased to 60% to enhance the hardness of the oxide film; 15 parts of dust suppressant and brightener are added to reduce wind and sand wear; and the immersion time is extended to 18 minutes to ensure that the calcium salt is fully precipitated.

[0057] Solar frame sealing in desert areas:

[0058] 1. Ingredient optimization:

[0059] Calcium salt accounts for 60% (mainly calcium phosphate); the gray suppressant and brightener is increased to 15 parts.

[0060] 2. Process adjustment:

[0061] Immersion time: 18 minutes; hot air drying temperature: 80℃, time: 20 minutes.

[0062] 3. Performance data:

[0063] Wind and sand abrasion test (quartz sand, flow rate 200g / min): surface roughness Ra increased from 0.6μm to 0.9μm, while traditional technology increased from 0.5μm to 1.8μm;

[0064] Thermal cycle stability: -40℃~60℃ cycle 500 times, no cracking of the oxide film, and the bonding strength of the sealing layer reaches 5B level (cross-hatch method GB / T9286).

[0065] Multi-dimensional verification system:

[0066] 1. Basic physical and chemical performance verification:

[0067] Sealing rate: Acid leaching weight loss method (GB / T8014.3), weight loss ≤ 25mg / dm 2 (National standard ≤30mg / dm 2 ); Phosphochromic acid method (ISO2085), weight loss ≤ 20 mg / dm 2 .

[0068] Surface properties: gloss retention rate ≥ 90% (measured by 60° gloss meter), roughness Ra ≤ 1.2μm (measured by stylus profilometer).

[0069] 2. Environmental tolerance performance verification:

[0070] Salt spray test (GB / T10125): No substrate corrosion after 2000h, weight loss ≤ 3mg / dm 2 (Traditional technology usually 8mg / dm 2 ).

[0071] Acid rain simulation: pH = 4 solution spraying for 240 hours, weight loss ≤ 1mg / dm 2 .

[0072] UV aging (GB / T16422.3): 500h color difference ΔE≤3 (national standard ≤5).

[0073] 3. Long-term reliability verification:

[0074] Humidity-freeze cycle (IEC61215): 85℃ / 85%RH damp heat for 1000h, +-40℃~85℃ freeze-thaw 50 times, no water vapor penetrates the interface between the frame and EVA film.

[0075] Dynamic mechanical load (DML, IEC61215): ±5400Pa cycles 2000 times, no cracking in the sealing layer (the cracking rate of traditional process is 30%).

[0076] On-site power station hanging samples: long-term monitoring of power stations in different climate zones to ensure that the cumulative weight loss in 5 years is ≤8mg / dm 2 , power generation efficiency attenuation rate ≤1.5% / year.

[0077] Conclusion: Through innovative component design, scenario-based process optimization and systematic verification scheme, the present invention has achieved comprehensive breakthroughs in environmental protection, performance, cost and reliability, filling many gaps in nickel-free sealing technology for solar aluminum profiles. It has significant technological advancement, industrial practicality and market competitiveness, and can effectively promote the green and sustainable development of the solar photovoltaic industry.

[0078] The contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0079] The standard parts used in the present invention can all be purchased from the market, and special-shaped parts can all be customized according to the instructions. The specific connection methods of each part adopt conventional means such as mature bolts, rivets, welding, etc. in the existing technology. The machinery, parts and equipment all adopt conventional models in the existing technology, and the circuit connection adopts the conventional connection method in the existing technology, which will not be described in detail here.

[0080] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A nickel-free sealing agent for aluminum frame oxidation of solar cells, characterized by: The aluminum frame oxidized nickel-free sealing agent is prepared by mixing the following raw materials: 10-50 parts of a zinc salt compound; 10-80 parts of a lithium salt compound; and 20-50 parts of a calcium salt compound. The following raw materials are also included by weight: 12kg of magnesium acetate, 5kg of ammonium acetate, 7kg of sodium acetate, 60kg of auxiliary agent, and 650kg of deionized water; The customized process of the aluminum frame oxidation nickel-free sealing agent in the solar energy scene is divided into conventional environment process, high humidity and heat / acid rain environment process and desert wind and sand environment process.

2. The nickel-free oxidized sealing agent for an aluminum frame of a solar cell according to claim 1, characterized in that: The zinc salt compound is a compound of zinc nitrate and zinc lactate.

3. The nickel-free oxidized sealing agent for aluminum frames of solar cells according to claim 1, characterized in that: The lithium salt compound is preferably lithium acetate.

4. The nickel-free oxidized sealing agent for an aluminum frame of a solar cell according to claim 1, characterized in that: The calcium salt compound is industrial grade calcium phosphate.

5. The nickel-free sealing agent for aluminum frame oxidation for solar cells according to claim 1, characterized in that: In the conventional environmental process, the concentration is 4%, pH is 4.5, the temperature is 25°C, and the immersion time is 16 minutes to ensure a balance between basic weather resistance and economy.

6. The nickel-free oxidized sealing agent for an aluminum frame of a solar cell according to claim 1, characterized in that: In the high humidity and heat / acid rain environment process, the concentration is 5%, the temperature is 30°C, the calcium salt ratio is increased to 40%, and the ultrasonic cleaning time is extended to 1 minute.

7. The nickel-free sealing agent for aluminum frame oxidation for solar cells according to claim 1, characterized in that: In the desert sand environment process, calcium salt accounts for 60% and is mainly calcium phosphate, and the dust suppression and brightening agent is increased to 15 parts.