Preparation process of light guide plate glass with hexagonal patterns and product
By using a rolling roll with continuous hexagonal convex grooves to roll molten silicate glass, a regular hexagonal concave texture structure is formed, which solves the problem of low light absorption efficiency of light guide glass in fine and ultra-thin photovoltaic modules, and improves mechanical reliability and optical performance.
Patent Information
- Application Number
- CN202511713217.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-20
- Publication Date
- 2026-01-20
AI Technical Summary
Existing light guide glass has low light absorption efficiency and limited applicability in refined and ultra-thin crystalline silicon photovoltaic modules. Traditional textured structures perform poorly under different lighting conditions and lack mechanical reliability.
The silicate glass melt is rolled using a rolling roll with continuous regular hexagonal raised patterns to form a hexagonal concave pattern structure. The rolling parameters, such as temperature, rate and pressure, are optimized to ensure that the concave pattern structure is regular and uniform, and that light is reflected and refracted more rationally in the concave pattern structure.
It improves the light transmission performance and mechanical reliability of the light guide plate glass, enhances the uniform distribution and absorption efficiency of light, reduces stress concentration, and has strong applicability, making it suitable for different lighting environments.
Smart Images
Figure CN121361947A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the field of light guide plate processing, in particular to a preparation process and product of a light guide plate glass with a hexagonal pattern. BACKGROUND
[0002] In the solar photovoltaic industry, light guide plate glass is one of the key components of crystalline silicon photovoltaic modules, and its main function is to protect the internal precise and fragile crystalline silicon cells from damage by water vapor, dust and external mechanical stress. In order to achieve the highest power generation efficiency, the cover plate glass must have high light transmittance to maximize the transmission of sunlight, and at the same time, it must have excellent mechanical strength to withstand extreme weather conditions such as wind pressure, snow load, hail impact, etc.
[0003] In order to further improve the power generation efficiency of photovoltaic modules, micro-texture structures are usually constructed on the inner surface of the light guide plate glass (i.e. the side facing the cells) to achieve light trapping effect. The principle is that when sunlight shines on the outer surface of the glass and penetrates to the inner surface, these texture structures can change the propagation path of the light, through multiple refraction and internal reflection, thereby significantly increasing the probability of light energy absorption by the crystalline silicon cells.
[0004] At present, the mainstream process of the above-mentioned light trapping texture is wet chemical etching. By etching the inner surface of the glass with an alkaline solution, a random distribution of approximately circular or quadrangular (tetrapod-shaped) concave or convex structures is formed. Although this process is mature and has low cost, it has the following disadvantages: Firstly, from the structural morphology, the texture formed by chemical etching, especially the quadrangular structure, exposes sharp edges and sharp tips on the surface. This sharp geometric morphology is prone to stress concentration at the sharp corners in ultra-thin and fine photovoltaic modules, potentially reducing the mechanical reliability and long-term durability of the light guide plate glass. Secondly, from the optical performance, the traditional circular or quadrangular texture performs well when the sunlight is perpendicular to the incident, but its optical capture ability has obvious angle dependence. In the morning, evening, overcast or cloudy conditions, etc., when the sunlight is mainly scattered or at a large angle, the existing texture will significantly reduce the ability to guide and capture light, limiting the application performance of the light guide plate glass. SUMMARY
[0005] In order to solve the problem that the existing light guide plate glass has low light absorption efficiency and low applicability when applied to fine and ultra-thin crystalline silicon photovoltaic modules, the present application provides a preparation process and product of a light guide plate glass with a hexagonal pattern.
[0006] In a first aspect, the present application provides a preparation process of a light guide plate glass with a hexagonal pattern, which adopts the following technical solution: A preparation process of a light guide plate glass with hexagonal patterns, comprising the following steps: The silicate glass liquid is calendered by using a calendering roller with continuous regular hexagonal convex patterns to obtain a light guide plate glass with hexagonal concave pattern structure; during calendering, one diagonal direction of the regular hexagonal convex pattern is horizontally arranged corresponding to the calendering direction of the calendering roller, and the length of the hexagonal convex pattern structure formed along the calendering direction is 1.18-1.25 times the length of the diagonal of the regular hexagonal convex pattern.
[0007] By adopting the above technical scheme, the silicate glass liquid is calendered by the calendering roller with regular hexagonal convex patterns to form a light guide plate glass and a hexagonal concave pattern structure on the surface of the light guide plate glass; during calendering, the diagonal direction of the regular hexagonal convex pattern is arranged corresponding to the calendering direction of the calendering roller, and the regular hexagonal convex pattern is calendered on the surface of the light guide plate glass under the calendering action of the calendering roller to form a hexagonal concave pattern structure which is elongated by 18-25% in length along the calendering direction and unchanged in width, thereby forming a hexagonal concave pattern structure with a specific shape; when sunlight irradiates the surface of the light guide plate glass, the transmitted sunlight is more orderly reflected under the action of the hexagonal concave pattern structure, so that the light guide is more uniform, thereby improving the light guide efficiency. Moreover, the regular hexagonal concave pattern structure of the present application has better light transmission performance than the quadrilateral structure, reduces the stress concentration of the light guide plate glass, and improves the structural stability.
[0008] The preparation process of the present application forms a hexagonal concave pattern structure with a specific shape and size on the surface of the light guide plate glass, and the hexagonal concave pattern structure is regular, which is applied to a fine and ultra-thin crystalline silicon photovoltaic module, has good light guide uniformity, high light guide efficiency, improves the transmission and absorption efficiency of sunlight, and has good mechanical reliability.
[0009] Preferably, the temperature of the calendering roller is 320-350 DEG C, the calendering speed is 2-3 m / min, and the calendering pressure is 0.4-0.7 MPa.
[0010] By adopting the above technical scheme, the temperature of the calendering roller can balance the calendering stress between the calendering roller and the silicate glass liquid during calendering, which improves the calendering stability and helps the shaping stability of the silicate glass liquid when it is separated from the calendering roller, so that the formed hexagonal concave pattern structure is not prone to burr or deformation, and also does not have problems such as cracks due to excessive stress. If the temperature of the calendering roller is too high, the shaping effect is poor, and the calendering roller is not easy to separate, which is prone to strain; if the temperature of the calendering roller is too low, the stress is not balanced, which causes cracks at the edges of the hexagonal concave pattern structure.
[0011] The preferred calendering rate and calendering pressure can make the silicate glass liquid uniformly stressed on the surface during the calendering process, uniformly and stably extended along the calendering direction, form elongation in the diagonal direction, and further form a specific and uniform hexagonal concave structure. If the calendering rate is too slow, the production efficiency is easily reduced, and if the calendering rate is too fast, the hexagonal concave structure formed by calendering is easily uneven. If the calendering pressure is too large, the edges of the hexagonal concave structure are easily uneven and have burrs, and if the calendering pressure is too small, the shape of the calendered hexagonal concave structure is easily deformed, and the shaping effect is poor.
[0012] Preferably, the temperature of the silicate glass liquid during calendering is 850-870°C, and the viscosity is 2500-3500 Pa·s.
[0013] By controlling the temperature and viscosity of the silicate glass liquid, the silicate glass liquid has good ductility and shaping performance, and it is easier to form a regular hexagonal concave structure during calendering, thereby improving the forming quality of the light guide plate glass.
[0014] Preferably, the side surface of the regular hexagonal convex ridge is inclined from the bottom to the surface along the direction close to the central axis of the regular hexagonal convex ridge, and the included angle between two adjacent regular hexagonal convex ridges along the height direction is 15-20°.
[0015] By adopting the above technical solution, the side surface of the regular hexagonal convex ridge is inclined, so that when light is incident on the side surface of the convex ridge, the direction of the reflected light is more dispersed, avoiding concentrated reflection of light, thereby improving the uniformity of light reflection. The included angle between two adjacent regular hexagonal convex ridges along the height direction is 15-20°, which can further optimize the reflection and refraction path of light between the convex ridges, increase the propagation distance and reflection times of light in the light guide plate glass, and capture more light and guide it to the battery piece, thereby effectively improving the absorption efficiency of sunlight.
[0016] Preferably, the height of the regular hexagonal convex ridge is 100-120 µm, and the opposite side distance of the bottom of the regular hexagonal convex ridge is 0.7-0.8 mm.
[0017] By optimizing the height and opposite side distance of the bottom of the regular hexagonal convex ridge, the light guide plate glass can form a more regular hexagonal concave structure with a more suitable size during the calendering process, and the light guide uniformity and light guide efficiency of the light guide plate glass can be improved, the transmission and absorption efficiency of sunlight can be enhanced, and the mechanical reliability of the light guide plate glass can also be improved.
[0018] Preferably, the distance between the bottoms of two adjacent regular hexagonal convex ridges is 20-40 µm.
[0019] By adopting the technical scheme, the hexagonal concave structure of the inner surface of the light guide plate glass formed by calendering is more regular and uniformly distributed, thereby improving the light guiding uniformity and light guiding efficiency of the light guide plate glass, increasing the transmission and absorption efficiency of sunlight, and helping to improve the mechanical reliability of the light guide plate glass.
[0020] Preferably, the surface of the regular hexagonal convex pattern is arranged in a convex arc shape.
[0021] By adopting the technical scheme, the regular hexagonal convex pattern of the convex arc surface helps to better guide and capture light under sunlight of different angles, reduces the angle dependence of optical capture capability, improves the transmission and absorption efficiency of sunlight, and makes the light guiding uniformity better.
[0022] Preferably, the calendering roller is made of alloy steel, the surface of the regular hexagonal convex pattern is coated with chromium, and the thickness of the chromium coating is 45-55µm.
[0023] By adopting the technical scheme, the alloy steel has high strength and good toughness, can withstand high pressure and friction during calendering, and ensures that the calendering roller is not easily deformed and damaged during long-term use. The chromium coating with a thickness of 45-55µm on the surface of the regular hexagonal convex pattern enables the calendering roller to have good high-temperature resistance, remain stable in a high-temperature calendering environment, enhance the wear resistance of the calendering roller surface, reduce the wear of the regular hexagonal convex pattern, prolong the service life of the calendering roller, improve the corrosion resistance of the calendering roller, prevent the calendering roller from being corroded by chemical components in the silicate glass liquid, and also prevent the silicate glass liquid from sticking to the calendering roller after calendering, thereby ensuring the smooth progress of the calendering process and the surface quality of the light guide plate glass.
[0024] Preferably, the silicate glass liquid is a sodium-calcium silicate glass liquid.
[0025] By adopting the technical scheme, the light guide plate glass made of the sodium-calcium silicate glass liquid has good structural stability and optical performance.
[0026] In a second aspect, the present application provides a light guide plate glass with a hexagonal pattern, which adopts the following technical scheme: A light guide plate glass with a hexagonal pattern is prepared by the above-mentioned preparation process of a light guide plate glass with a hexagonal pattern. The inner surface of the light guide plate glass forms a plurality of uniformly and spacedly distributed hexagonal concave structures.
[0027] By adopting the technical scheme, the inner surface of the light guide plate glass is formed with a plurality of uniform and spaced hexagonal concave structures, which have regular characteristics. When applied to a fine and ultra-thin crystalline silicon photovoltaic module, the light guide uniformity is good, the efficiency is high, the transmission and absorption efficiency of sunlight can be improved, the stress concentration problem caused by sharp geometric features is avoided, the mechanical reliability and long-term durability are good, the angle dependence of optical capture capability is low, good performance can be achieved in different light environments, and the applicability is strong.
[0028] In summary, the present application includes at least one of the following beneficial technical effects: 1. The silicate glass liquid is calendered using a calendering roller with continuous regular hexagonal convex patterns, so as to obtain a light guide plate glass with hexagonal concave structures, and one of the diagonal directions of the regular hexagonal convex patterns is horizontally arranged in the calendering direction of the calendering roller. The length of the hexagonal convex structure formed by calendering along the calendering direction is 1.18-1.25 times the length of the diagonal of the regular hexagonal convex pattern. The regular hexagonal concave structure of the present application has better light transmission performance than the quadrilateral structure, reduces the stress concentration of the light guide plate glass, and improves the structural stability. The regular hexagonal concave structure is applied to a fine and ultra-thin crystalline silicon photovoltaic module, and has good light guide uniformity, high light guide efficiency, improved transmission and absorption efficiency of sunlight, and good mechanical reliability.
[0029] 2. The side surface of the regular hexagonal convex pattern is inclined from the bottom to the surface along the direction close to the central axis of the regular hexagonal convex pattern, and the included angle between the two adjacent regular hexagonal convex patterns along the height direction is 15-20°. The reflection and refraction of light in the hexagonal concave structure are more reasonable, the capture and utilization efficiency of light is further improved, and the optical performance of the light guide plate glass is enhanced.
[0030] 3. The surface of the regular hexagonal convex pattern is arranged in a convex arc shape, which can make the light scatter and refract more uniformly on the convex arc surface, reduce the reflection loss of light, and improve the propagation uniformity of light in the light guide plate glass. BRIEF DESCRIPTION OF DRAWINGS
[0031] Figure 1 is a schematic view of the calendering direction of the calendering roller in the preparation process of the present application and the surface pattern of the corresponding calendering roller; Figure 2 is a longitudinal sectional view of the regular hexagonal convex pattern of the calendering roller in the preparation process of the present application; Figure 3 is a schematic view of the hexagonal concave structure of the light guide plate glass surface corresponding to the calendering direction in the preparation process of the present application. DETAILED DESCRIPTION
[0032] The application will be further described in detail below with reference to the examples. Embodiment Embodiment 1
[0033] Embodiment 1 discloses a preparation process of a light guide plate glass with hexagonal patterns, comprising the following steps: S1, melt the silicate glass liquid raw material at high temperature to prepare a silicate glass liquid, the silicate glass liquid is a sodium calcium silicate glass liquid, which is composed of the following components by weight percentage: 72.5% of silicon dioxide, 13.2% of sodium oxide, 9% of calcium oxide, 4% of magnesium oxide, 1% of aluminum oxide, less than 0.015% of iron oxide, 0.28% of sulfur trioxide and other unavoidable impurities. It should be noted that the high-temperature melting in step S1 is a common preparation process of silicate glass liquid in the art, which will not be described in detail here. S2, refer to the attached Figures 1-3 , use the calendering roller with continuous regular hexagonal convex patterns to calender the silicate glass liquid, the temperature of the calendering roller is 320℃, the calendering speed is 2m / min, the calendering pressure is 0.4MPa, the temperature of the silicate glass liquid during calendering is 850℃, and the viscosity is 3500Pa•s, to prepare a light guide plate glass semi-finished product with hexagonal concave structure; during calendering, one of the diagonal directions of the regular hexagonal convex pattern is horizontally arranged corresponding to the calendering direction of the calendering roller, and the length of the hexagonal convex pattern formed along the calendering direction is 1.18 times the length of the diagonal of the regular hexagonal convex pattern.
[0034] The parameters of the calendering roller are as follows: the calendering roller is made of alloy steel, specifically 20CrNiMo alloy structural steel, the surface of the regular hexagonal convex pattern is chromium coating, and the thickness of the chromium coating is 45µm; refer to Figure 2 , the side surface of the regular hexagonal convex pattern is inclined from the bottom to the surface along the direction close to the central axis of the regular hexagonal convex pattern, the included angle between the adjacent two regular hexagonal convex patterns along the height direction is denoted as θ, θ=15°, the height of the regular hexagonal convex pattern is denoted as H, H=100µm, and the bottom side distance of the regular hexagonal convex pattern is denoted as b, b=0.7mm. The distance between the bottoms of the adjacent two regular hexagonal convex patterns is denoted as a, a=20µm. The surface of the regular hexagonal convex pattern is arranged in a convex arc shape; S3, anneal the prepared light guide plate glass, which is divided into four stages: the first stage temperature is 545℃, the annealing rate is 5℃ / min, the second stage temperature is 340℃, the annealing rate is 15℃ / min, the third stage temperature is set to 130℃, the annealing rate is 25℃ / min, and the fourth stage temperature is 20℃, the annealing rate is 25℃ / min; S4, anneal the prepared light guide plate glass semi-finished product, and then perform tempering treatment and cutting to prepare a light guide plate glass; the tempering process is a conventional process in the art, which will not be described in detail here.
[0035] The drawings are referred to Figure 2 and Figure 3 The thickness of the light guide plate glass of the embodiment is 1.5 mm, the inner surface of the light guide plate glass forms a plurality of uniform and spaced hexagonal concave structures, one of the diagonal lines of the hexagonal concave structure is 1.18 times the length of the diagonal line of the regular hexagonal convex structure, and the side distance of the hexagonal concave structure and the spacing between two adjacent hexagonal concave structures are unchanged.
[0036] Example 2-3 Example 2-3 differs from Example 1 in that the preparation process parameters are different, see Table 1 below for details.
[0037] Table 1 Parameter table of Examples 1-3
[0038] Example 4
[0039] Example 4 differs from Example 1 in that the temperature of the calender roll is 120°C, and the others are the same as Example 1.
[0040] Example 5
[0041] Example 5 differs from Example 1 in that the temperature of the sodium calcium silicate glass liquid is 800°C, the viscosity is 7000 Pa·s, and the others are the same as Example 1.
[0042] Example 6
[0043] Example 6 differs from Example 1 in that the included angle between the two adjacent regular hexagonal convex structures along the height direction is 50°, and the others are the same as Example 1.
[0044] Example 7
[0045] Example 7 differs from Example 1 in that the height of the regular hexagonal convex structure is 180µm, and the others are the same as Example 1.
[0046] Example 8
[0047] Example 8 differs from Example 1 in that the surface of the regular hexagonal convex structure is a plane, and the others are the same as Example 1. Comparative Example
[0048] Comparative Example 1 Comparative Example 1 differs from Example 1 in that the calendering pressure is 0.8 MPa, the length of the hexagonal convex structure formed by calendering along the calendering direction is 1.35 times the length of the diagonal line of the regular hexagonal convex structure, and the others are the same as Example 1.
[0049] Comparative Example 2 The difference between Comparative Example 2 and Example 1 is that the hexagonal concave structure formed by calendering is the same as the regular hexagonal convex, and the others are the same as Example 1. Performance test:
[0050] The performance test of the light guide plate glass prepared in Examples 1-8 and Comparative Examples 1-2 is as follows: 1. Light transmittance detection Using a photovoltaic glass transmittance tester, the solar light transmittance of the light guide plate glass (unit: %) is tested, and the test results are recorded; 2. Light guide uniformity test In a dark room, using an LED light source, 9 measurement grid points are set in the effective light-emitting area of the light guide plate glass, the brightness meter is aligned with one side of the hexagonal concave structure of the light guide plate, the test angle is kept vertical, the test distance is 2 cm, the test probe is moved, and the brightness value of each measurement grid point is measured in turn. The brightness uniformity is calculated, and the brightness uniformity = the measured value of the lowest point of brightness / the measured value of the highest point of brightness*100%, the smaller the value, the worse the brightness uniformity.
[0051] 3. Hexagonal concave structure defect test of light guide plate glass Observe whether the hexagonal concave structure of the light guide plate glass appears deformation and crack, and record the test results, The performance test data of the light guide plate glass prepared in Examples 1-8 and Comparative Examples 1-2 are as follows, see Table 2 below.
[0052] Table 2 Performance data of light guide plate glass prepared in Examples 1-8 and Comparative Examples 1-2
[0053] It can be concluded from Examples 1-3 that by optimizing the parameter range of the preparation process of the application, the light guide plate glass prepared has good light transmittance and light guide uniformity, and no deformation and crack defects occur during calendering.
[0054] It can be concluded from Examples 1 and 4 that optimizing the temperature of the calendering roller can improve the stability of calendering. In Example 4, the calendering temperature is reduced, the light guide plate glass prepared has slight cracks, and the solar light transmittance decreases.
[0055] It can be concluded from Examples 1 and 5 that optimizing the temperature and viscosity of the silicate glass liquid can improve the stability of the light guide plate glass prepared. In Example 5, the temperature of the silicate glass liquid is reduced, and the viscosity is increased. The light guide plate glass prepared has slight deformation defects, and the solar light transmittance decreases.
[0056] It can be concluded from Examples 1 and 6-8 that by optimizing the parameters of the calendering roller, the light guiding uniformity and stability of the prepared light guide plate glass can be significantly improved. In Example 6, the included angle of the adjacent two regular hexagonal convex patterns is increased, the solar transmittance of the prepared light guide plate glass is reduced, and the brightness uniformity is significantly reduced. In Example 7, the height of the regular hexagonal convex pattern is increased, so that the hexagonal concave structure of the prepared light guide plate glass is deepened, and the solar transmittance and brightness uniformity of the prepared light guide plate glass are reduced. In Example 8, the surface of the regular hexagonal convex pattern is set as a plane, and the transmittance and brightness uniformity of the prepared light guide plate glass are reduced. From the above analysis, it can be concluded that the parameters in the calendering process of the present application are mutually coordinated and balanced, thereby enabling the prepared light guide plate glass to have a higher solar transmittance while having a better light guiding uniformity and no defects.
[0057] It can be concluded from Examples 1 and Comparative Examples 1-2 that the length of the hexagonal convex pattern formed by calendering along the calendering direction is 1.18-1.25 times the diagonal length of the regular hexagonal convex pattern, which can enable the prepared light guide plate glass to have a better solar transmittance while having a better light guiding uniformity. In Comparative Example 1, the elongation multiple is increased, and in Comparative Example 2, no elongation is performed, and the solar transmittance and light guiding uniformity of the prepared light guide plate glass are reduced.
[0058] The specific embodiments are merely an explanation of the present application, and are not a limitation of the present application. Those skilled in the art can make modifications to the embodiments without creative contribution after reading the present specification, and as long as the modifications are within the scope of the claims of the present application, they are protected by the Patent Law.
Claims
1. A process for producing a light guide plate glass having a hexagonal pattern, characterized by, The method comprises the following steps: The method comprises the following steps:
2. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The temperature of the calendering roller is 320-350 ℃, the calendering speed is 2-3 m / min, and the calendering pressure is 0.4-0.7 MPa.
3. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The temperature of the silicate glass liquid during calendering is 850-870 ℃, and the viscosity is 2500-3500 Pa·s.
4. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The side surface of the regular hexagonal convex pattern is inclined from the bottom to the surface along the direction close to the central axis of the regular hexagonal convex pattern, and the included angle between two adjacent regular hexagonal convex patterns along the height direction is 15-20°.
5. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The height of the regular hexagonal convex pattern is 100-120 µm, and the bottom side distance of the regular hexagonal convex pattern is 0.7-0.8 mm.
6. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The spacing between the bottoms of two adjacent regular hexagonal convex patterns is 20-40 µm.
7. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The surface of the regular hexagonal convex pattern is arranged in a convex arc shape.
8. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The calendering roller is made of alloy steel, the surface of the regular hexagonal convex pattern is coated with chromium, and the thickness of the chromium coating is 45-55 µm.
9. The process for producing a light guide plate glass with a hexagonal pattern according to claim 1, wherein The silicate glass liquid is a sodium-calcium silicate glass liquid.
10. A light guide plate glass having a hexagonal pattern, characterized by A light guide plate glass with a hexagonal pattern is prepared by the method of any one of claims 1-9, and the inner surface of the light guide plate glass forms a plurality of uniform and spaced hexagonal concave structures.