Preparation method of wear-resistant hydrophobic coated glass and novel anti-dust photovoltaic module

Abstract

The invention discloses a preparation method of wear-resistant hydrophobic coated glass and a novel anti-dust photovoltaic module, and solves the problems of large power loss, unbalanced coating performance and the like caused by dust deposition of a small-dip-angle photovoltaic module. When the coated glass is prepared, after photovoltaic glass is subjected to ultrasonic pretreatment, hard coating sol is prepared from TBT, and the hard coating sol is cured into a wear-resistant bottom layer through UV irradiation; preparing hydrophobic sol from vinyltrimethoxysilane and polyvinylpyrrolidone composite fibers, performing electrospinning, ultrasonically removing polyvinylpyrrolidone, and performing FOTS modification to form a hydrophobic upper layer; the contact angle is larger than 150 degrees, the hardness is larger than or equal to 5H, and the light transmittance is larger than or equal to 93.5%; the assembly comprises the coated glass, a battery layer and back glass. Short frames are cancelled, and long frames are reserved; and short edges and corners are sealed by butyl adhesive tapes with low water vapor transmittance, and the rest are bonded by adhesive films. The coating has the advantages of dust accumulation zone removal, power loss and hot spot risk reduction, coating durability, excellent assembly waterproofness, power generation capacity and service life improvement of a power station, and suitableness for distributed small-dip-angle scenes.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic technology, and in particular to a method for preparing wear-resistant hydrophobic coated glass and a novel dust-resistant photovoltaic module. Background Technology

[0002] In practical applications of distributed photovoltaic (PV) power stations, a large number of PV modules need to be installed on industrial and commercial rooftops. These rooftops are often made of corrugated steel sheets, and due to structural limitations, the installation tilt angle of the modules is generally small, typically only 2-5°. Under these small tilt angle installation scenarios, the core technical challenges facing PV modules are dust accumulation and shading, insufficient coating performance, waterproofing failure, an imbalance between mechanical performance and installation convenience, and low light transmission efficiency. Existing technologies struggle to simultaneously achieve both practicality and reliability. Specific shortcomings are as follows:

[0003] Traditional photovoltaic modules typically have a short frame that protrudes above the glass panel. When rainwater washes over them, surface tension causes rainwater and atmospheric dust to accumulate at the frame. After evaporation, this forms a dust accumulation band at the bottom, resulting in severe localized shading. This dust accumulation band has a significant impact on power output, far exceeding that of uniform surface dust accumulation. It can also easily trigger hot spot effects and even burn out the module. Existing solutions, such as frameless modules, can reduce dust accumulation, but their corners are prone to breakage and their installation strength is insufficient. Anti-dust accumulation modules either require custom-made frames or simply have holes drilled in the frame, neither of which can fundamentally eliminate the dust accumulation band; they can only prolong the cleaning cycle.

[0004] Existing coating designs for hydrophobic photovoltaic glass have shortcomings: if wear resistance is desired, a high-temperature sintering process is required, which is energy-intensive and can easily cause glass deformation. If the high-temperature process is omitted, the coating hardness is low, it is easily worn, and the hydrophobic properties degrade quickly. At the same time, traditional raw materials are either expensive or have poor resistance to ultraviolet decomposition, resulting in a short coating lifespan and the need for frequent glass replacement, which significantly increases the maintenance cost of the power plant throughout its entire life cycle.

[0005] The short sides and corners of photovoltaic modules are the main pathways for water vapor penetration. However, most existing modules use full film lamination sealing and do not have reinforced designs for these water-prone areas. Conventional films have high water vapor permeability. In long-term use, water vapor can easily penetrate into the module, causing corrosion of the cell grid lines and failure of the passivation layer, which in turn leads to rapid power decay. The module's design life is difficult to meet industry standards, and it needs to be replaced in advance to ensure power generation.

[0006] There is a contradiction between mechanical performance and installability of existing components: frameless components have no frame support, have weak resistance to wind and snow, have a high rate of damage during transportation, and require custom brackets for installation; framed components have better mechanical performance, but the traditional frame design can easily obstruct rainwater flow and often lacks a cushioning structure, making them prone to damage during handling and installation due to collisions, making it difficult to balance "damage resistance" and "installation efficiency".

[0007] The power generation efficiency of a module depends on the synergy between the light transmittance of the glass and the light absorption efficiency of the solar cell. However, existing technologies have shortcomings. Traditional ultra-white glass has limited light transmittance. After coating with a hydrophobic coating, the light reflection loss will increase due to the mismatch in refractive index. At the same time, the anti-reflection design on the surface of the solar cell is insufficient, and a large amount of sunlight escapes due to reflection and cannot be converted into electrical energy, which restricts the improvement of module power generation.

[0008] Therefore, this invention proposes a method for preparing wear-resistant hydrophobic coated glass and a novel anti-dust photovoltaic module. Summary of the Invention

[0009] One objective of this invention is to propose a method for preparing wear-resistant and hydrophobic coated glass and a novel anti-dust photovoltaic module. This invention can completely eliminate the dust accumulation band at the bottom of small-tilt photovoltaic modules, avoiding significant power loss and hot spot risks caused by dust shading. Simultaneously, by optimizing the coating materials and processes, coated glass with high wear resistance, superhydrophobicity, and high light transmittance can be prepared under low-temperature conditions, reducing raw material and energy costs. Furthermore, it strengthens the sealing design in areas prone to water ingress, delaying power decay and extending service life. Through frame structure optimization, it reduces the risk of breakage while ensuring mechanical strength and installation convenience. Finally, by combining coating refractive index matching and cell anti-reflection design, it improves light absorption efficiency to increase power generation, comprehensively solving the technical pain points of existing photovoltaic modules in terms of dust accumulation, coating performance, waterproofing, mechanical practicality, and light transmittance efficiency.

[0010] A method for preparing wear-resistant hydrophobic coated glass according to an embodiment of the present invention includes the following steps:

[0011] S1. Pretreatment: The photovoltaic glass is ultrasonically cleaned sequentially with acetone, ethanol and deionized water, and then dried with nitrogen gas after cleaning.

[0012] S2. Preparation of hard coating gel: Tetraethyl titanate and ethanol are mixed and stirred in a molar ratio of 1:8:0.5. Acetylacetone is slowly added to the mixture, followed by deionized water. The pH of the system is adjusted to 2.5-3.5 with hydrochloric acid, and then 3-7 wt% of [the following is missing from the original text] is added. Core-shell particles are ultrasonically dispersed and then aged in a water bath to form a transparent, hard coating sol.

[0013] S3. Underlying Coating and Curing: A hard coating sol is applied to the photovoltaic glass surface using ultraviolet light, while simultaneously cured by heating, forming a dense, nanoscale coating on the photovoltaic glass surface. Network underlayer coating;

[0014] S4. Preparation of hydrophobic coating gel: Mix vinyltrimethoxysilane, ethanol and deionized water in a volume ratio of 1:12:3. Add 10-15 wt% polyvinylpyrrolidone to the mixture and stir until the polyvinylpyrrolidone is completely dissolved. Then add deionized water containing 0.1 wt% ammonium persulfate and react at 40°C for 2 hours to form a hydrophobic coating sol.

[0015] S5. Top Coating: The hydrophobic coating sol is deposited on the surface of the bottom coating using an electrospinning method to form a micron-scale vinyltrimethoxysilane and polyvinylpyrrolidone composite fiber top coating precursor.

[0016] S6. Post-treatment: The photovoltaic glass coated with the upper coating precursor is immersed in deionized water and ultrasonically treated to dissolve polyvinylpyrrolidone to form a porous structure with a pore size of 100-300nm. Then it is immersed in a 1wt% perfluorooctyltrimethoxysilane ethanol solution, removed and dried to obtain a wear-resistant hydrophobic coated glass with a total double coating thickness of 300-500nm.

[0017] Furthermore, in step S1, the ultrasonic cleaning is performed in stages:

[0018] First, ultrasonically clean with acetone for 30-60 minutes, then ultrasonically clean with ethanol for 30-60 minutes, and finally ultrasonically clean with deionized water for 30-60 minutes. After each cleaning, rinse with deionized water 1-2 times to ensure that there is no cleaning agent residue.

[0019] Furthermore, in step S2, After ultrasonic dispersion of the core-shell particles, the particle size distribution was detected by a laser particle size analyzer to ensure that D10 ≥ 30 nm, D90 ≤ 150 nm, and no obvious agglomerates. During the aging process, the particles were stirred once every 6 hours for 5-10 minutes each time to ensure the uniformity of the sol.

[0020] Furthermore, in step S3, the bottom layer coating is applied by dip coating or spray coating of hard coating sol. The coating rate is 5-10 mm / s during dip coating and the spraying pressure is 0.2-0.4 MPa during spray coating. After coating, the coating is first left to stand at room temperature for 5-10 minutes, and then cured by ultraviolet irradiation and auxiliary heating.

[0021] Furthermore, in step S5, a roller-type receiving device is used during the electrospinning process to ensure that the vinyltrimethoxysilane and polyvinylpyrrolidone composite fibers are uniformly deposited on the surface of the bottom coating, with the fiber diameter controlled at 200-500 nm and the inter-fiber porosity at 30-50%.

[0022] Furthermore, in step S6, constant temperature oscillation is used during the FOTS ethanol solution impregnation to ensure that the FOTS fully penetrates into the porous structure. After drying, X-ray photoelectron spectroscopy is used to detect the elemental composition of the coating surface to ensure... The relative content of functional groups is ≥15 at.

[0023] A novel dust-resistant photovoltaic module includes wear-resistant hydrophobic coated glass, a battery layer, a back glass, an internal sealing structure, and an external frame structure.

[0024] The battery layer is disposed beneath the wear-resistant, hydrophobic coated glass. The battery layer comprises monocrystalline silicon cells, polycrystalline silicon cells, or thin-film cells, connected in series or parallel via solder ribbons. Each cell has a 50-100 μm thick anti-reflective film on its surface. The back glass is disposed beneath the battery layer, opposite the wear-resistant, hydrophobic coated glass. The back glass is made of ultra-clear patterned glass, tempered glass, or a transparent ceramic substrate for photovoltaic applications, with a thickness of 2.5-4 mm. The internal sealing structure uses butyl tape applied to the short sides and corners of the module. The butyl tape is a structural butyl rubber adhesive with a water vapor transmission rate of 0.01-0.1 g / L. The cross-section is an isosceles trapezoid, and after high-temperature lamination at 130-150℃ and 0.1-0.3MPa, the cross-section is flat with a thickness of 1.0-1.5mm. After lamination, butyl tape is tightly bonded to the wear-resistant hydrophobic coated glass and the back glass, respectively. Except for the short sides and corners, the remaining areas inside the module are bonded with adhesive film. The adhesive film is an ethylene-vinyl acetate copolymer film or a polyolefin elastomer film with a thickness of 0.45-0.6mm. The cut shape of the adhesive film perfectly matches the contour of the non-butyl tape sealing area inside the module, ensuring adhesion. After bonding, there are no bubbles or voids remaining. The external frame structure eliminates the short frame of the component and installs rubber corner protectors at the glass corners. The rubber corner protectors are bonded to the laminated component body using high-temperature resistant silicone. The long frame of the component is retained. The long frame is made of aluminum alloy or magnesium-aluminum alloy and is 2-3mm shorter than the component body. Mounting holes with a spacing of 150-200mm are reserved on the long frame for component installation using pressure blocks or screws. A buffer pad is installed on the inner wall of the long frame. The buffer pad is molded and fits tightly to the inner wall of the long frame.

[0025] Furthermore, the adhesive film is an ethylene-vinyl acetate copolymer adhesive film or a polyolefin elastomer adhesive film, and the shape of the adhesive film is cut to match the contour of the non-butyl tape sealing area in the component to ensure that no air bubbles remain after bonding.

[0026] Furthermore, the wear-resistant hydrophobic coated glass retains ≥90% of its performance after durability testing, including a contact angle >140° after UV aging test, no peeling or blistering of the coating after salt spray test, and a light transmittance decrease of ≤1% after 1000 Taber abrasion tests.

[0027] Furthermore, the long frame is made of aluminum alloy, and a buffer pad is set on the inner wall of the long frame. The buffer pad is made of EPDM rubber with a thickness of 0.5-1mm, which is used to reduce the collision damage between the long frame and the laminate body during component transportation.

[0028] The beneficial effects of this invention are:

[0029] 1. In this invention, the water droplet contact angle of the wear-resistant hydrophobic coated glass is >150° and the roll-off angle is <5°, placing it in a superhydrophobic state. The superhydrophobic surface creates an air cushion between the water droplet and the glass, making the water droplet approximately spherical. Under the influence of gravity, the droplet quickly rolls off the inclined surface of the module, simultaneously carrying away atmospheric dust particles with a diameter <100μm deposited on the surface, thus preventing dust accumulation. Secondly, the module eliminates the traditional short frame, eliminating the 3mm height difference between the frame and the glass panel. This completely solves the problem of rainwater accumulating at the frame due to surface tension and forming a dust accumulation band after evaporation. It ensures that rainwater and dust flow away from the edge of the module without obstruction, preventing local dust accumulation and light shading. This eliminates the dust accumulation band at the bottom of small-tilt photovoltaic modules, avoiding more than 30% power loss for horizontally arranged modules and more than 70% for vertically arranged modules. It reduces the risk of module burnout caused by hot spot effect from the root, greatly improving the long-term power generation stability of the module.

[0030] 2. The introduction of a hard base coating in this invention Core-shell particles, The nucleus provides low expansion. Shell reinforcement and The network's binding force forms a dense, nanoscale wear-resistant structure, replacing the traditional high-temperature sintering process. A hardness of 5H can be achieved with auxiliary heating at 60-80℃, significantly reducing energy consumption. Tetraethyl titanate (TBT) is used instead of traditional tetraethyl orthosilicate (TES), making the TBT hydrolysis rate easier to control, and the raw material unit price is lower than TEOS. Simultaneously, the coating's wear resistance is retained. The upper hydrophobic coating uses short-chain perfluorooctyltrimethoxysilane. With high group bond energy, it has better resistance to UV decomposition than long-chain fluorides, avoiding the degradation of hydrophobic properties of the coating after long-term exposure to sunlight and reducing the maintenance cost of frequent glass replacement.

[0031] 3. In this invention, structural butyl tape is applied to the short sides and corners of the module. This tape has a low water vapor permeability and an isosceles trapezoidal cross-section. After high-temperature lamination, the tape adheres tightly to the front and back glass, forming a dual waterproof structure of physical barrier and chemical bonding. This prevents external water vapor from penetrating into the module. The cross-linking degree between the solar cells and the adhesive film is ≥85%, and the yellowing index of the adhesive film is ≤1.5. This further reduces the path of water vapor penetration through the adhesive film, avoiding grid line corrosion and passivation layer failure caused by water vapor erosion of the solar cells, and fundamentally delaying power decay.

[0032] 4. This invention retains a long frame, whose cross-sectional strength and mounting hole design allow for a secure connection to the bracket via pressure blocks and screws, providing the necessary support against wind and snow. This addresses the weakness of frameless modules in resisting wind and snow pressure. EPDM rubber corner protectors are fitted at the glass corners, and these protectors are bonded to the module body using high-temperature resistant silicone, absorbing impacts during handling or installation. An EPDM buffer pad is installed on the inner wall of the long frame to reduce friction and collisions between the frame and the laminated body during transportation, lowering the risk of breakage. The long frame is 2-3mm shorter than the module to prevent protruding edges from obstructing rainwater flow. Simultaneously, the pre-drilled 150-200mm spacing mounting holes allow for direct adaptation to conventional photovoltaic brackets, eliminating the need for customized mounting parts and improving on-site installation efficiency.

[0033] 5. In this invention, the total thickness of the wear-resistant and hydrophobic coating is controlled at 280-520 nm, and the bottom layer... The refractive index of the network and the upper porous vinyltrimethoxysilane and polyvinylpyrrolidone composite fiber structure are matched, which can reduce the reflection loss of light at the interface between the coating and the glass, and greatly improve the light transmittance. The silica anti-reflective film on the surface of the cell forms a gradient refractive index transition with the air and the cell substrate, further reducing the reflectivity of light on the surface of the cell and reducing light escape loss. Secondly, the coating has no obvious optical defects, avoiding energy loss caused by light scattering, ensuring that more sunlight is converted into electrical energy, and directly improving the power generation efficiency of the module. Attached Figure Description

[0034] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0035] Figure 1 This is a schematic flowchart of a method for preparing wear-resistant hydrophobic coated glass proposed in this invention.

[0036] Figure 2 This is a schematic diagram of the internal structure of a novel dust-resistant photovoltaic module proposed in this invention;

[0037] Figure 3 This is a cut shape diagram of the encapsulant film for a novel dust-resistant photovoltaic module proposed in this invention;

[0038] Figure 4 This is a design drawing of the outer frame of a novel dust-proof photovoltaic module proposed in this invention. Detailed Implementation

[0039] To make the technical means and objectives and effects of the present invention easier to understand, the embodiments of the present invention will be described in detail below with reference to specific illustrations.

[0040] This embodiment aims to disclose in detail a method for preparing wear-resistant hydrophobic coated glass and a complete technical solution for a novel anti-dust photovoltaic module, ensuring that each process step is repeatable and each structural parameter is operable. The following description is based on specific operational details, equipment parameters and testing standards.

[0041] like Figure 1 As shown, this invention discloses a method for preparing wear-resistant hydrophobic coated glass, comprising the following steps:

[0042] S1. Pretreatment: The photovoltaic glass is ultrasonically cleaned sequentially with acetone, ethanol and deionized water, and then dried with nitrogen gas after cleaning.

[0043] Specifically, a photovoltaic ultra-clear glass with a specification of 1600mm×1000mm×3.2mm was selected as the substrate. The glass has an initial light transmittance of ≥91.5% and a bending strength of ≥90MPa to ensure that the substrate performance meets the requirements of subsequent coating.

[0044] During pretreatment, segmented ultrasonic cleaning is performed sequentially using acetone, ethanol, and deionized water, as follows:

[0045] First, place the glass in an ultrasonic cleaning tank, add acetone until the glass is completely submerged, and turn on the ultrasonic cleaner for 30-60 minutes to remove industrial oil and organic residues from the glass surface.

[0046] Then, acetone was drained, the cleaning tank was rinsed twice with deionized water, ethanol was added to immerse the glass again, and ultrasonic cleaning was performed for 30-60 minutes at the same power and frequency to further remove stubborn organic impurities.

[0047] Finally, drain the ethanol, replace with deionized water, and continue ultrasonic cleaning for 30-60 minutes to remove any remaining cleaning agent residue adhering to the surface.

[0048] After each ultrasonic cleaning cycle, the glass surface is rinsed 1-2 times with deionized water at a flow rate of 2-3L / min, with each rinse lasting 30 seconds, to ensure no cleaning agent residue remains.

[0049] After cleaning, transfer the glass to a nitrogen drying device, introduce nitrogen gas with a purity of ≥99.9%, and blow it evenly from the top to the bottom of the glass until there are no watermarks or visible impurities on the glass surface, then set it aside.

[0050] S2. Preparation of hard coating gel: Tetraethyl titanate and ethanol are mixed and stirred in a molar ratio of 1:8:0.5. Acetylacetone is slowly added to the mixture, followed by deionized water. The pH of the system is adjusted to 2.5-3.5 with hydrochloric acid, and then 3-7 wt% of [the following is missing from the original text] is added. Core-shell particles are ultrasonically dispersed and then aged in a water bath to form a transparent, hard coating sol.

[0051] The tetraethyl titanate has a purity of ≥98% and the anhydrous ethanol has a purity of ≥99.7%. Add both to a 500mL three-necked flask and place it in a constant temperature water bath at 25-30℃. Stir at a speed of 300-500r / min for 15-20min until the mixture is homogeneous and transparent.

[0052] Then, acetylacetone was slowly added to the mixture through a separatory funnel while stirring during the addition. After the addition was completed, stirring was continued for 10 minutes to allow acetylacetone and TBT to fully coordinate. Deionized water was then added dropwise to the flask using a constant pressure dropping funnel, and the addition time was controlled to be 15-20 minutes to avoid localized hydrolysis that could lead to precipitation.

[0053] After the addition is complete, adjust the pH of the system to 2.5-3.5 with a 0.1-1 mol / L hydrochloric acid solution. During the adjustment process, monitor the pH in real time with a precision pH meter to ensure that the pH value remains stable within the target range.

[0054] Then add 3-7 wt% of [amount missing] Core-shell particles, in which The nucleus diameter is 30-60 nm. With a shell thickness of 10-20 nm and a D50 of 50-100 nm, the three-necked flask was transferred to an ultrasonic disperser and ultrasonically dispersed for 15-30 min.

[0055] After ultrasonication, a small amount of sol was taken and the particle size distribution was detected by a laser particle size analyzer to ensure that the detection results meet the requirements of D10≥30nm, D90≤150nm, and no aggregates with a particle size >500nm.

[0056] Finally, the three-necked flask was placed back into a constant temperature water bath at 40℃±2℃ for 24 hours of aging. During the aging process, the flask was stirred at 300 rpm for 5-10 minutes every 6 hours to prevent particle sedimentation. The final product was a transparent, sediment-free, hard coating sol, with the sol viscosity controlled at 20-50. .

[0057] S3. Underlying Coating and Curing: A hard coating sol is applied to the photovoltaic glass surface using ultraviolet light, while simultaneously cured by heating, forming a dense, nanoscale coating on the photovoltaic glass surface. Network underlayer coating;

[0058] Specifically, the hard coating sol is applied to the pretreated photovoltaic glass surface using either dip coating or spray coating methods. The specific operations for both coating methods are as follows:

[0059] If the dip coating method is used, fix the glass on the clamp of the dip coating machine, adjust the dip coating rate to 5-10 mm / s, immerse the glass vertically into the hard coating sol, hold for 5 seconds and then lift it at a uniform speed to ensure that the coating thickness is uniform.

[0060] If using the spraying method, select a fan-shaped nozzle with a diameter of 0.5mm, adjust the spraying pressure to 0.2-0.4MPa, the spraying distance to 15-20cm, and the spraying rate to 5-10mL / min. Move the glass at a uniform speed of 50mm / s to ensure that the coating is free of drips and missed areas.

[0061] After coating, place the glass in an environment with room temperature and humidity of 40-50% for 5-10 minutes to allow the sol to initially level and reduce surface defects.

[0062] The glass was then transferred to a UV curing apparatus, in which the UV lamp had a wavelength of 365nm ± 5nm and a light intensity of [missing information]. The vertical distance between the ultraviolet lamp and the glass surface should be controlled at 10-15cm;

[0063] Simultaneously turn on the hot air heating system and blow clean hot air at 60-80℃ onto the glass surface. Ultraviolet irradiation and hot air heating are carried out simultaneously, and the curing time is 1-3 minutes.

[0064] After curing, a film thickness gauge was used to take one test point at the center and one at each of the four corners of the glass to measure the thickness of the bottom coating, which was 100-250nm, and the thickness difference between each point was ≤10nm, to ensure the uniformity of the coating.

[0065] S4. Preparation of hydrophobic coating gel: Mix vinyltrimethoxysilane, ethanol and deionized water in a volume ratio of 1:12:3. Add 10-15 wt% polyvinylpyrrolidone to the mixture and stir until the polyvinylpyrrolidone is completely dissolved. Then add deionized water containing 0.1 wt% ammonium persulfate and react at 40°C for 2 hours to form a hydrophobic coating sol.

[0066] Specifically, vinyltrimethoxysilane and anhydrous ethanol are added to a 250 mL beaker and stirred at 200-300 r / min for 10 min at room temperature of 25°C to ensure thorough mixing.

[0067] Then add 10-15 wt% polyvinylpyrrolidone and continue stirring for 30-40 minutes. During this period, use a glass rod to dip a small amount of the mixture every 5 minutes to observe until the polyvinylpyrrolidone is completely dissolved, the mixture is homogeneous and transparent and there are no visible particles.

[0068] Then, add deionized water containing 0.1 wt% ammonium persulfate dropwise to the mixture. The ammonium persulfate needs to be completely dissolved in deionized water beforehand. Keep the stirring rate constant during the dropwise addition process and control the dropwise addition time to 10-15 minutes.

[0069] After the addition is complete, transfer the beaker to a constant temperature water bath at 40℃±0.5℃ and react at the constant temperature for 2 hours. Stir for 5 minutes every 30 minutes during the reaction to prevent uneven local concentration.

[0070] After the reaction is complete, use a rotational viscometer to measure the viscosity of the hydrophobic coating sol, ensuring the viscosity is 50-100. This meets the subsequent electrospinning requirements.

[0071] S5. Top Coating: The hydrophobic coating sol is deposited on the surface of the bottom coating using an electrospinning method to form a micron-scale vinyltrimethoxysilane and polyvinylpyrrolidone composite fiber top coating precursor.

[0072] Specifically, an electrospinning coating method is used to deposit a hydrophobic coating sol onto the surface of the underlying coating. The specific parameters of the electrospinning device are set as follows:

[0073] The spinning nozzle is made of stainless steel needle with an inner diameter of 0.2 mm. The spinning voltage is controlled by a high voltage power supply at 15-20 kV. The receiving distance is 15-20 cm. The spinning rate is controlled by a micro-injection pump at 0.5-1 mL / h.

[0074] To ensure coating uniformity, a roller-type receiving device is used. The roller is made of polytetrafluoroethylene, with a diameter of 15cm and a length of 1700mm. The rotation speed is controlled at 50-100r / min. The glass coated with the base layer is fixed on the surface of the roller, so that the glass surface is parallel to the tip of the needle.

[0075] The electrospinning process is carried out in a constant temperature and humidity chamber, with the ambient temperature controlled at 25-30℃ and the ambient humidity controlled at 40-50%.

[0076] During the electrospinning process, the fiber deposition state was observed with an optical microscope every 10 minutes to ensure that the diameter of the vinyltrimethoxysilane and polyvinylpyrrolidone composite fiber was controlled at 200-500 nm and that there was no obvious accumulation between the fibers.

[0077] After coating, the thickness of the upper coating precursor is measured using a film thickness gauge to ensure that the thickness is 180-270nm. At the same time, the porosity between fibers is measured using image analysis to ensure that the porosity is 30-50%.

[0078] S6. Post-processing: The photovoltaic glass coated with the upper coating precursor is immersed in deionized water and ultrasonically treated to dissolve polyvinylpyrrolidone to form a porous structure with a pore size of 100-300nm. Then it is immersed in a 1wt% perfluorooctyltrimethoxysilane ethanol solution, taken out and dried to obtain a wear-resistant hydrophobic coated glass with a total thickness of 300-500nm for the double coating.

[0079] Specifically, glass coated with the upper coating precursor is placed in an ultrasonic cleaning tank, deionized water is added until the glass is completely submerged, and the ultrasonic instrument is turned on for ultrasonic treatment for 5 min ± 1 min. The ultrasonic vibration accelerates the dissolution of PVP, so that the composite fiber layer forms a porous structure.

[0080] After the ultrasound is completed, the glass is removed and allowed to drain naturally. Then it is immersed in a 1 wt% perfluorooctyltrimethoxysilane ethanol solution. The immersion container is made of polytetrafluoroethylene, and the solution level is 5 cm above the top of the glass to ensure that the glass is completely submerged.

[0081] Transfer the impregnation container to a constant temperature water bath at 50℃±2℃, and turn on the shaking device at the same time. Impregnate for 30-60 minutes under constant temperature shaking to ensure that FOTS fully penetrates into the porous structure and combines with the hydroxyl groups on the fiber surface.

[0082] After impregnation, remove the glass, gently wipe off any excess solution with a lint-free cloth, and then place it in a vacuum oven to dry for 2 hours ± 10 minutes at 50℃±2℃ to prevent the coating from oxidizing during the drying process.

[0083] After drying, a wear-resistant and hydrophobic coated glass with a total double-coating thickness of 280-520 nm was obtained. The glass was then subjected to performance testing.

[0084] Using a contact angle measuring instrument, the water droplet contact angle was measured to be >150° and the roll-off angle to be <5°.

[0085] The hardness of the wear-resistant coated pencil was measured to be ≥5H using a pencil hardness tester;

[0086] The transmittance of the glass was measured to be ≥93.5% using a UV-Vis spectrophotometer.

[0087] X-ray photoelectron spectroscopy was used to detect the elements on the coating surface to ensure... The relative content of functional groups is ≥15 at.

[0088] like Figure 2-4 As shown, after obtaining qualified wear-resistant and hydrophobic coated glass, the novel anti-dust photovoltaic module is assembled. The core structure of the module includes wear-resistant and hydrophobic coated glass, a battery layer, a back glass, an internal sealing structure, and an external frame structure. The specific assembly process is as follows:

[0089] First, the battery layer parameters are determined, and monocrystalline silicon solar cells are selected. The solar cells are connected in series by tin-plated copper strips. A silica antireflective film with a thickness of 50-100 nm is prepared on the surface of the series-connected solar cell string using the sol-gel method, ensuring that the reflectivity of the antireflective film in the 400-1100 nm wavelength band is ≤2%.

[0090] Secondly, the back glass is selected, and ultra-clear patterned glass is used, with an impact resistance of ≥ With a light transmittance of ≥90%, the back glass is placed below the battery layer and arranged opposite to the wear-resistant and hydrophobic coated glass to ensure that the battery layer is completely covered by the two glass panels.

[0091] The construction of the internal sealing structure requires strict control over the following details:

[0092] Butyl tape made of structural butyl rubber adhesive is applied to the short sides and corners of the component. The water vapor transmission rate of this butyl tape needs to be tested to ensure it is 0.01-0.1 g / L. / sky;

[0093] Butyl tape has an isosceles trapezoidal cross-section with an upper base width of 3-5mm and a lower base width of 5-8mm. It is applied using an automatic tape applicator with an applicability of ±0.2mm, ensuring that the tape is free from offset and wrinkles.

[0094] Place the component structure with the butyl tape applied into the laminator, and set the laminator parameters as follows:

[0095] The heating rate is 5℃ / min. After heating to 130-150℃, the temperature is held for 10 minutes. The lamination pressure is 0.1-0.3MPa. After lamination, the material is allowed to cool naturally to room temperature. At this point, the butyl tape has a flat cross-section, a thickness of 1.0-1.5mm, and is tightly bonded to the wear-resistant hydrophobic coated glass and back glass without gaps.

[0096] Except for the short sides and corners, the rest of the components are bonded with polyolefin elastomer film. The film is cut with a laser cutting machine with a cutting accuracy of ±0.1mm to ensure that the cut shape completely matches the contour of the non-butyl tape sealing area.

[0097] The degree of crosslinking of the adhesive film needs to be tested to ensure that it is ≥85%, and after being placed at 85℃ and 85%RH for 1000 hours, the yellowing index of the adhesive film is ≤1.5.

[0098] In addition, the optimization of the outer border structure should follow these steps:

[0099] The short frame of the component is removed, and rubber corner protectors are fitted at the glass corners. The rubber corner protectors are injection molded from EPDM rubber with a thickness of 1-2mm and a Shore hardness of 60-70A. The inside of the corner protector is coated with high-temperature resistant silicone with a coating thickness of 0.5mm±0.1mm. Then, the corner protector is fitted at the glass corner and a pressure of 50N is applied and held for 30s to ensure that the silicone is tightly bonded to the laminated component body. After bonding, it is left to stand for 24 hours and the bonding strength is tested to ensure ≥1MPa.

[0100] The long frame of the component is retained. The long frame is made of 6063-T5 aluminum alloy extrusion molding with a cross-sectional size of 40mm×20mm. The length is 2-3mm shorter than the main body of the component. After extrusion, it is anodized and the oxide film thickness is ≥10μm.

[0101] Pre-drill mounting holes on the long frame, using a CNC drilling machine to machine holes with a diameter of 6-8mm and a spacing of 150-200mm, for mounting components using clamping blocks or screws;

[0102] A buffer pad is installed on the inner wall of the long frame. The buffer pad is made of EPDM rubber and is bonded to the inner wall of the long frame with butyl rubber. After bonding, the bonding strength is tested to ensure ≥0.8MPa, which can effectively reduce the collision damage between the long frame and the laminated body during component transportation.

[0103] It is important to note that the assembled new dust-resistant photovoltaic modules need to undergo comprehensive performance testing to verify the effectiveness of the technical solution:

[0104] The durability test of wear-resistant hydrophobic coated glass must meet the following requirements: after ultraviolet aging test, the water droplet contact angle is still >140°.

[0105] Salt spray resistance test was conducted, and the coating showed no peeling or blistering after the test.

[0106] After 1000 Taber abrasion tests, the light transmittance decreased by ≤1%.

[0107] The overall mechanical properties of the components must be tested according to GB / T 19064-2016 to ensure wind pressure resistance ≥2400Pa and snow pressure resistance ≥5400Pa;

[0108] During the drop test, the component was dropped from 1 meter without any glass breakage or frame deformation, ensuring the reliability and safety of the component in practical applications.

[0109] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing wear-resistant hydrophobic coated glass, characterized in that, Includes the following steps: S1. Pretreatment: The photovoltaic glass is ultrasonically cleaned sequentially with acetone, ethanol and deionized water, and then dried with nitrogen gas after cleaning. S2. Preparation of hard coating gel: Tetraethyl titanate and ethanol are mixed and stirred in a molar ratio of 1:8:0.

5. Acetylacetone is slowly added to the mixture, followed by deionized water. The pH of the system is adjusted to 2.5-3.5 with hydrochloric acid, and then 3-7 wt% of [the following is missing from the original text] is added. Core-shell particles are ultrasonically dispersed and then aged in a water bath to form a transparent, hard coating sol. S3. Underlying Coating and Curing: A hard coating sol is applied to the photovoltaic glass surface using ultraviolet light, while simultaneously cured by heating, forming a dense, nanoscale coating on the photovoltaic glass surface. Network underlayer coating; S4. Preparation of hydrophobic coating gel: Mix vinyltrimethoxysilane, ethanol and deionized water in a volume ratio of 1:12:

3. Add 10-15 wt% polyvinylpyrrolidone to the mixture and stir until the polyvinylpyrrolidone is completely dissolved. Then add deionized water containing 0.1 wt% ammonium persulfate and react at 40°C for 2 hours to form a hydrophobic coating sol. S5. Top Coating: The hydrophobic coating sol is deposited on the surface of the bottom coating using an electrospinning method to form a micron-scale vinyltrimethoxysilane and polyvinylpyrrolidone composite fiber top coating precursor. S6. Post-treatment: The photovoltaic glass coated with the upper coating precursor is immersed in deionized water and ultrasonically treated to dissolve polyvinylpyrrolidone to form a porous structure with a pore size of 100-300nm. Then it is immersed in a 1wt% perfluorooctyltrimethoxysilane ethanol solution, removed and dried to obtain a wear-resistant hydrophobic coated glass with a total double coating thickness of 300-500nm.

2. The method for preparing wear-resistant hydrophobic coated glass and the novel dust-resistant photovoltaic module according to claim 1, characterized in that, In step S1, the ultrasonic cleaning is performed in stages: First, ultrasonically clean with acetone for 30-60 minutes, then ultrasonically clean with ethanol for 30-60 minutes, and finally ultrasonically clean with deionized water for 30-60 minutes. After each cleaning, rinse with deionized water 1-2 times to ensure that there is no cleaning agent residue.

3. The method for preparing wear-resistant hydrophobic coated glass and the novel dust-resistant photovoltaic module according to claim 1, characterized in that, In step S2 After ultrasonic dispersion of the core-shell particles, the particle size distribution was detected by a laser particle size analyzer to ensure that D10 ≥ 30 nm, D90 ≤ 150 nm, and no obvious agglomerates. During the aging process, the particles were stirred once every 6 hours for 5-10 minutes each time to ensure the uniformity of the sol.

4. The method for preparing wear-resistant hydrophobic coated glass and the novel dust-resistant photovoltaic module according to claim 1, characterized in that, In step S3, the bottom layer coating is applied by dip coating or spray coating of hard coating sol. The coating rate is 5-10 mm / s when dip coating and 0.2-0.4 MPa when spray coating. After coating, it is first left to stand at room temperature for 5-10 minutes, and then cured by ultraviolet irradiation and auxiliary heating.

5. The method for preparing wear-resistant hydrophobic coated glass and the novel dust-resistant photovoltaic module according to claim 1, characterized in that, In step S5, a roller-type receiving device is used during the electrospinning process to ensure that the vinyltrimethoxysilane and polyvinylpyrrolidone composite fibers are uniformly deposited on the surface of the bottom coating, with the fiber diameter controlled at 200-500 nm and the inter-fiber porosity at 30-50%.

6. The method for preparing wear-resistant hydrophobic coated glass and the novel anti-dust photovoltaic module according to claim 1, characterized in that, In step S6, constant temperature oscillation is used during the FOTS ethanol solution impregnation to ensure that the FOTS fully penetrates into the porous structure. After drying, X-ray photoelectron spectroscopy is used to detect the elemental composition of the coating surface to ensure... The relative content of functional groups is ≥15 at.

7. A novel dust-resistant photovoltaic module, comprising a method for preparing wear-resistant hydrophobic coated glass according to any one of claims 1-6, characterized in that, It includes wear-resistant hydrophobic coated glass, battery layer, back glass, internal sealing structure, and external frame structure; The battery layer is disposed beneath the wear-resistant, hydrophobic coated glass. The battery layer comprises monocrystalline silicon cells, polycrystalline silicon cells, or thin-film cells, connected in series or parallel via solder ribbons. Each cell has a 50-100 μm thick anti-reflective film on its surface. The back glass is disposed beneath the battery layer, opposite the wear-resistant, hydrophobic coated glass. The back glass is made of ultra-clear patterned glass, tempered glass, or a transparent ceramic substrate for photovoltaic applications, with a thickness of 2.5-4 mm. The internal sealing structure uses butyl tape applied to the short sides and corners of the module. The butyl tape is a structural butyl rubber adhesive with a water vapor transmission rate of 0.01-0.1 g / L. The cross-section is an isosceles trapezoid, and after high-temperature lamination at 130-150℃ and 0.1-0.3MPa, the cross-section is flat with a thickness of 1.0-1.5mm. After lamination, butyl tape is tightly bonded to the wear-resistant hydrophobic coated glass and the back glass, respectively. Except for the short sides and corners, the remaining areas inside the module are bonded with adhesive film. The adhesive film is an ethylene-vinyl acetate copolymer film or a polyolefin elastomer film with a thickness of 0.45-0.6mm. The cut shape of the adhesive film perfectly matches the contour of the non-butyl tape sealing area inside the module, ensuring adhesion. After bonding, there are no bubbles or voids remaining. The external frame structure eliminates the short frame of the component and installs rubber corner protectors at the glass corners. The rubber corner protectors are bonded to the laminated component body using high-temperature resistant silicone. The long frame of the component is retained. The long frame is made of aluminum alloy or magnesium-aluminum alloy and is 2-3mm shorter than the component body. Mounting holes with a spacing of 150-200mm are reserved on the long frame for component installation using pressure blocks or screws. A buffer pad is installed on the inner wall of the long frame. The buffer pad is molded and fits tightly to the inner wall of the long frame.

8. A novel dust-resistant photovoltaic module according to claim 7, characterized in that, The adhesive film is an ethylene-vinyl acetate copolymer adhesive film or a polyolefin elastomer adhesive film. The shape of the adhesive film is cut to match the contour of the non-butyl tape sealing area in the component to ensure that there are no air bubbles left after bonding.

9. A novel dust-resistant photovoltaic module according to claim 7, characterized in that, The wear-resistant hydrophobic coated glass retains ≥90% of its performance after durability testing. Specifically, after UV aging testing, the contact angle is still >140°, the coating shows no peeling or blistering after salt spray testing, and the light transmittance decreases by ≤1% after 1000 Taber abrasion tests.

10. A novel dust-resistant photovoltaic module according to claim 7, characterized in that, The long frame is made of aluminum alloy, and a buffer pad is set on the inner wall of the long frame. The buffer pad is made of EPDM rubber with a thickness of 0.5-1mm to reduce collision damage between the long frame and the laminate body during component transportation.

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