A laminated photovoltaic and LED composite photoelectric integrated glass

Abstract

The application discloses a laminated photovoltaic and LED composite photoelectric integrated glass, and belongs to the technical field of photovoltaic building integration and building energy-saving composite components, which comprises, from the outdoor side to the indoor side, a front light-transmitting glass layer, a first encapsulating glue layer, a photovoltaic charging device, a second encapsulating glue layer, an LED light-emitting device, a third encapsulating glue layer and a rear glass layer arranged in sequence in layers; the photovoltaic charging device and the LED light-emitting device are electrically connected through a conductive cable; the photovoltaic charging device is arranged above, and the LED light-emitting device is arranged below, in a non-shading layer sequence layout; compared with the existing LED integrated mode in which the LED is arranged above or in the same layer and is spaced, the LED device and the circuit no longer shield the photovoltaic light-receiving surface. The disclosed actual measurement data shows that the photovoltaic conversion efficiency is improved by 15% to 30%, the crystalline silicon type can reach more than 22%, and the thin film type can reach more than 15%, thereby effectively solving the long-existing technical bottleneck of 'integration must be shielded' in the industry, and enabling the photovoltaic building integration component to exert the maximum power generation potential in a limited area.

Description

Technical Field

[0001] This invention relates to the field of building-integrated photovoltaics and building energy-saving composite components, and more specifically, to a laminated photovoltaic and LED composite optoelectronic integrated glass. Background Technology

[0002] With the continued advancement of green building and zero-carbon city policies, building-integrated photovoltaics (BIPV) has become a core development direction for building energy conservation and new energy utilization. In existing building glass components, photovoltaic glass is used to convert solar energy into electricity, while LED photovoltaic glass is used for light transmission or dynamic decoration. Both types of components are used in building curtain walls, skylights, and shading components. Currently, there are attempts in the market to integrate photovoltaic and LED functions into the same glass component, mainly using a structure where LED devices are placed above photovoltaic modules or photovoltaic cells and LED beads are arranged in the same layer at intervals. However, the above integration methods have significant drawbacks in practical applications. First, the LED devices and their wiring directly block the light-receiving surface of the photovoltaic cells, and actual measurements show that the photovoltaic conversion efficiency decreases by 20% to 40%, severely weakening the photovoltaic power generation capacity. Second, in the integrated component, the LEDs still rely on external mains power and cannot utilize the electricity generated by their own photovoltaics, resulting in high overall energy consumption of the component, which does not conform to the original design intention of building energy conservation. Third, the photovoltaic layer and LED layer lack sufficient bonding and isolation structure, resulting in insufficient interlayer bonding strength. This makes them prone to problems such as delamination, water ingress, and aging during long-term outdoor use. The lifespan of these components is generally only 5 to 8 years, far below the conventional lifespan requirement of over 15 years for architectural glass. Fourth, in existing products, the photovoltaic layer only has power generation function, and the LED layer only has light emission function. These two functions are independent, failing to achieve a true integrated closed loop of power generation, supply, and light emission.

[0003] To address the aforementioned issues, this technology provides a laminated photovoltaic and LED composite optoelectronic integrated glass. It employs a stacked arrangement with the photovoltaic charging device on top and the LED light-emitting device below, and multiple layers of encapsulating film are placed between each functional layer. The glass is integrally formed through a vacuum lamination and hot-pressing process. Simultaneously, it incorporates an energy storage capacitor and a voltage regulator module to enable direct power supply from the photovoltaic to the LED. This structure eliminates the shading of the photovoltaic light-receiving surface by the LED, achieves a self-powered closed loop within the component, and improves overall structural stability and waterproof and weather-resistant performance through multi-layer lamination encapsulation. It aims to solve the technical challenges of low power generation efficiency, reliance on external power supply, structural instability, and functional fragmentation in existing integrated technologies. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a laminated photovoltaic and LED composite optoelectronic integrated glass, which solves the aforementioned problems.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solution: a laminated photovoltaic and LED composite optoelectronic integrated glass, comprising a front light-transmitting glass layer, a first encapsulating adhesive layer, a photovoltaic charging device, a second encapsulating adhesive layer, an LED light-emitting device, a third encapsulating adhesive layer, and a rear glass layer arranged sequentially along the direction from the outdoor side to the indoor side; the photovoltaic charging device and the LED light-emitting device are electrically connected by a conductive cable.

[0006] Preferably, the photovoltaic charging device is a crystalline silicon photovoltaic cell or a thin-film photovoltaic cell, and the panel transmittance of the crystalline silicon photovoltaic cell or the thin-film photovoltaic cell is 20% to 40%; the LED light-emitting device is a transparent flexible printed circuit board, and an LED lamp bead array is welded on the upper surface of the transparent flexible printed circuit board.

[0007] Preferably, the first encapsulating layer, the second encapsulating layer, and the third encapsulating layer are each independently selected from polyvinyl butyral film, ethylene-vinyl acetate copolymer film, or ionic intermediate film film; the single-layer thickness of the first encapsulating layer, the second encapsulating layer, and the third encapsulating layer is each independently between 0.38 mm and 1.52 mm.

[0008] Preferably, the front transparent glass layer is an ultra-clear tempered glass panel, and the rear glass layer is a tempered glass panel or a laminated safety glass panel; the thickness of each of the front transparent glass layer and the rear glass layer is independently 5mm to 12mm.

[0009] Preferably, a miniature electrolytic capacitor and a DC voltage regulator module are connected in series on the conductive cable between the photovoltaic charging device and the LED light-emitting device; the miniature electrolytic capacitor and the DC voltage regulator module are encapsulated inside the second encapsulation layer.

[0010] Preferably, the nominal capacitance of the miniature electrolytic capacitor is 1000μF to 5000μF, and the output voltage of the DC voltage regulator module is 3.3V to 24V.

[0011] Preferably, the vertical distance between the lower surface of the photovoltaic charging device and the upper surface of the LED light-emitting device is 0.38 mm to 1.52 mm; the parallelism error between the lower surface of the photovoltaic charging device and the upper surface of the LED light-emitting device is no greater than 0.5 mm.

[0012] Preferably, the front translucent glass layer, the first encapsulating adhesive layer, the photovoltaic charging device, the second encapsulating adhesive layer, the LED light-emitting device, the third encapsulating adhesive layer, and the rear glass layer are integrally hot-pressed in a vacuum laminating furnace; the hot-pressing temperature of the vacuum laminating furnace is 120°C to 140°C, the hot-pressing pressure is 1.0MPa to 1.2MPa, and the heat and pressure holding time is 30 minutes to 40 minutes.

[0013] Preferably, the overall transmittance of the laminate between the front transparent glass layer and the rear glass layer is 45% to 60% in the visible light band; the photoelectric conversion efficiency of the photovoltaic charging device under standard test conditions is not less than 15%; and the luminous uniformity of the LED light-emitting device under rated operating voltage is not less than 90%.

[0014] Preferably, the edges of the laminate formed by the front transparent glass layer, the first encapsulating adhesive layer, the photovoltaic charging device, the second encapsulating adhesive layer, the LED light-emitting device, the third encapsulating adhesive layer, and the rear glass layer are coated with butyl rubber sealing strips; the overall waterproof rating of the laminate reaches IP67, and there is no delamination or delamination phenomenon in the high and low temperature cycle test from -40℃ to 80℃.

[0015] Compared with the prior art, the present invention provides a laminated photovoltaic and LED composite optoelectronic integrated glass, which has the following beneficial effects: This new type of laminated photovoltaic and LED composite optoelectronic integrated glass adopts an unobstructed layered layout with the photovoltaic charging device on top and the LED light-emitting device below. Compared with existing integration methods where LEDs are on top or spaced apart in the same layer, the LED devices and circuits no longer block the photovoltaic light-receiving surface. Actual test data shows that the photovoltaic conversion efficiency is improved by 15% to 30%, with crystalline silicon reaching over 22% and thin-film reaching over 15%. This effectively solves the long-standing technical bottleneck of "integration inevitably causing shading" in the industry, enabling building-integrated photovoltaic components to maximize their power generation potential within a limited area.

[0016] This type of laminated photovoltaic and LED composite optoelectronic integrated glass connects a micro-energy storage capacitor and a voltage regulator module in series between the photovoltaic charging device and the LED light-emitting device. The electricity generated by the photovoltaic is stored and regulated before being directly supplied to the LED, eliminating the need for the LED to be connected to the mains power. Data shows that the component can save 120 to 180 kWh of electricity per square meter per year. Based on an industrial electricity price of 0.8 yuan / kWh, this translates to annual electricity cost savings of 96 to 144 yuan / ㎡. Building lighting energy consumption is reduced by more than 80%, truly achieving a closed-loop integrated operation of "power generation-energy storage-lighting".

[0017] This type of laminated photovoltaic and LED composite optoelectronic integrated glass adopts a three-layer encapsulation film lamination structure. It is hot-pressed and cured in a vacuum lamination oven at 120℃ to 140℃ and 1.0MPa to 1.2MPa, achieving seamless bonding across all layers and a waterproof rating of IP67. Test data shows that the component passed high and low temperature cycling tests from -40℃ to 80℃ and a 6000-hour UV aging test without delamination or aging cracking, exhibiting a service life of no less than 15 years, far exceeding the 5 to 8 years lifespan of existing integrated products, thus meeting the requirements for long-term outdoor use of architectural glass.

[0018] This type of laminated photovoltaic and LED composite optoelectronic integrated glass integrates photovoltaic power generation and LED lighting functions into a single glass component, replacing the traditional scattered combination of "architectural glass + photovoltaic panel + LED lamps". Data from the disclosure meeting shows that the construction cycle is shortened by 40%, installation costs are reduced by 30%, auxiliary material costs are reduced by 25%, and the overall production cost per square meter is reduced by 30% to 40% compared to similar imported products. At the same time, the component has a light transmittance of 45% to 60%, balancing lighting and decorative functions, and is suitable for various architectural scenarios such as curtain walls, skylights, and sunshade components. Detailed Implementation

[0019] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] This invention provides a technical solution: Example 1

[0021] A type of laminated photovoltaic and LED composite optoelectronic integrated glass has the following structure from the outdoor side to the indoor side: a front transparent glass layer, a first encapsulating adhesive layer, a photovoltaic charging device, a second encapsulating adhesive layer, an LED light-emitting device, a third encapsulating adhesive layer, and a rear glass layer.

[0022] The front translucent glass layer is made of 6mm thick ultra-clear tempered glass with a visible light transmittance of 88%. The rear glass layer is made of 6mm thick ordinary tempered glass. Both the front and rear glass layers have been finely ground, with rounded corners (R5 radius) and no burrs on the edges.

[0023] The first, second, and third encapsulating layers all use a 0.76mm thick PVB film. The first encapsulating layer is bonded to the inner side of the front transparent glass layer, the second encapsulating layer is sandwiched between the photovoltaic charging device and the LED light-emitting device, and the third encapsulating layer is bonded between the LED light-emitting device and the rear glass layer.

[0024] The photovoltaic charging device uses monocrystalline silicon photovoltaic cells with a panel transmittance of 25%, dimensions of 980mm × 480mm, and a thickness of 2.5mm. The light-receiving side of the photovoltaic cell faces the outdoor area, while the back side has positive and negative electrode leads.

[0025] The LED light-emitting device uses a transparent flexible printed circuit board. The circuit board substrate is a 0.2mm thick polyimide film with a light transmittance of approximately 85%. 120 surface-mount LEDs are soldered onto the circuit board surface using a reflow soldering process. The LEDs are evenly arranged in an array with a spacing of 15mm x 15mm. Positive and negative electrode connection points are located on the back of the flexible circuit board.

[0026] The positive and negative electrode leads of the photovoltaic charging device are connected in series with the positive and negative electrode input points of the LED light-emitting device via tin-plated copper wires. A miniature electrolytic capacitor and a DC voltage regulator module are also connected in series in this circuit. The miniature electrolytic capacitor has a capacitance of 2200μF and a voltage rating of 16V. The DC voltage regulator module is an LM2596 step-down regulator module with an output voltage set to 5V. Both the miniature electrolytic capacitor and the DC voltage regulator module are encapsulated within a second encapsulation layer, ensuring no relative displacement between them and the photovoltaic charging device and the LED light-emitting device.

[0027] During the stacking and assembly process, a dedicated positioning fixture is used to fix the positions of the photovoltaic charging device and the LED light-emitting device, ensuring that the vertical distance between the lower surface of the photovoltaic charging device and the upper surface of the LED light-emitting device is equal to the thickness of the second encapsulating adhesive layer, i.e., 0.76 mm. Calibration with a laser rangefinder ensures that the parallelism error between the two is controlled within 0.3 mm.

[0028] After the lamination assembly is completed, the entire assembly is placed in a vacuum lamination oven. First, a vacuum is drawn to -0.095 MPa to completely remove air between the layers. Then, the temperature is raised to 130°C, and a pressure of 1.1 MPa is applied, maintaining the temperature and pressure for 35 minutes. During this process, the three layers of PVB film completely melt and cross-link, bonding the front transparent glass layer, photovoltaic charging device, LED light-emitting device, and rear glass layer into a single unit.

[0029] After cooling from the furnace, the four edges of the laminate are sealed. A two-component butyl rubber sealing strip is applied to the edges, with a width of 8mm and a thickness of 2mm, covering all gaps between the front and rear glass layers.

[0030] The performance of the prepared composite optoelectronic integrated glass was tested. Under standard sunlight conditions (1000W / m², AM1.5, 25℃), the photoelectric conversion efficiency of the photovoltaic charging device was measured to be 18.5%. Under 5V DC power supply, the luminous uniformity of the LED array reached 92%, with no obvious dark areas or bright spots. Using a spectrophotometer, the overall transmittance of the glass in the visible light band was measured to be 52%. An impact resistance test was conducted according to GB / T 5137.1 standard; a 226g steel ball was dropped from a height of 1.2m and impacted the center of the glass without breaking it, and the PVB adhesive layer did not delaminate. A waterproof test was conducted according to IP67 standard; the glass was completely immersed in 1m of water for 30 minutes. After removal, there was no short circuit in the internal circuit, and the LEDs emitted light normally. In a high and low temperature cycling test chamber, a cycle of -40℃ for 2 hours and 80℃ for 2 hours constituted one cycle. After 50 consecutive cycles, the laminate showed no delamination, no bubbles, and no delamination. Based on comprehensive assessment, the product in this embodiment is designed to have a service life of more than 15 years. Example 2

[0031] The front transparent glass layer is made of 5mm thick ultra-clear tempered glass, and the rear glass layer is made of 5mm thick laminated safety glass.

[0032] The first, second, and third encapsulating layers all use EVA film with a thickness of 1.14 mm. The crosslinking degree of the EVA film is ≥75%, and the melt flow index is 25 g / 10 min.

[0033] The photovoltaic charging device uses copper indium gallium selenide thin-film photovoltaic cells with a panel transmittance of 35%, a size of 1200mm×600mm, and a thickness of 1.8mm.

[0034] The LED light-emitting device uses a transparent flexible printed circuit board. The circuit board substrate is a PET film with a thickness of 0.3mm and a light transmittance of approximately 78%. 240 COB-packaged LED beads are soldered onto the surface of the circuit board, with the beads evenly arranged at a spacing of 10mm × 10mm.

[0035] The series circuit uses a miniature electrolytic capacitor with a capacitance of 3300μF, and the DC voltage regulator module is an AMS1117-3.3 type voltage regulator module with an output voltage of 3.3V.

[0036] The vacuum lamination curing process parameters are as follows: vacuum to -0.095MPa, temperature rise to 135℃, pressure of 1.0MPa, and heat and pressure hold for 40 minutes.

[0037] The composite optoelectronic integrated glass prepared in this embodiment has a photovoltaic conversion efficiency of 12.5% ​​(an inherent characteristic of thin-film batteries), an overall light transmittance of 58%, and an LED luminous uniformity of 91%. The results of high and low temperature cycling tests and ultraviolet aging tests all meet the requirements for outdoor use in buildings. Example 3

[0038] The front transparent glass layer is made of 10mm thick ultra-clear tempered glass, and the rear glass layer is made of 10mm thick tempered glass.

[0039] The first encapsulating layer uses a 0.38mm thick SGP film, the second encapsulating layer uses a 0.76mm thick PVB film, and the third encapsulating layer uses a 0.38mm thick SGP film. The selection of different film types optimizes the bonding strength between different interfaces.

[0040] The photovoltaic charging device uses polycrystalline silicon photovoltaic cells with a panel transmittance of 22%, a size of 600mm×600mm, and a thickness of 3.0mm.

[0041] The LED lighting device uses a transparent flexible printed circuit board with 60 RGB full-color LED beads soldered on the surface. The beads are arranged with a spacing of 25mm×25mm.

[0042] The miniature electrolytic capacitor in the series circuit has a capacitance of 1500μF, and the DC voltage regulator module outputs 12V.

[0043] The vacuum lamination curing process parameters are as follows: vacuum to -0.095MPa, temperature rise to 125℃, pressure of 1.2MPa, and heat and pressure hold for 30 minutes.

[0044] The composite optoelectronic integrated glass prepared in this embodiment is suitable for use as a shading component in building curtain walls. It has an overall light transmittance of 48%, a photovoltaic conversion efficiency of 16.2%, and an LED luminous uniformity of 93%. Example 4

[0045] The front transparent glass layer is made of 8mm thick ultra-clear tempered glass, and the rear glass layer is made of 8mm thick laminated safety glass.

[0046] All three encapsulation layers use 1.52mm thick PVB film.

[0047] The photovoltaic charging device uses monocrystalline silicon photovoltaic cells with a light transmittance of 20%. The LED lighting device uses a transparent flexible printed circuit board with 300 LED beads soldered to its surface.

[0048] The series-connected miniature electrolytic capacitor has a capacitance of 4700μF, and the DC voltage regulator module outputs 24V.

[0049] In terms of edge sealing, in addition to coating the butyl rubber sealing strip, an aluminum alloy U-shaped edging is added to the outside of the sealing strip. The edging thickness is 1.5mm and the edging width is 12mm. It is bonded and fixed to the glass edge with structural adhesive to further enhance the edge waterproofing and mechanical impact resistance.

[0050] The composite optoelectronic integrated glass prepared in this embodiment has an overall light transmittance of 46%, a photovoltaic conversion efficiency of 19.2%, and an LED luminous uniformity of 94%. Testing showed that it achieved an IP67 waterproof rating, exhibiting no water seepage at the edges and no condensation inside after high and low temperature cycling tests and a 6000-hour UV aging test.

[0051] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A laminated photovoltaic and LED composite optoelectronic integrated glass, characterized in that, It includes a front transparent glass layer, a first encapsulating layer, a photovoltaic charging device, a second encapsulating layer, an LED light-emitting device, a third encapsulating layer, and a rear glass layer, which are stacked sequentially from the outdoor side to the indoor side; the photovoltaic charging device and the LED light-emitting device are electrically connected by a conductive cable.

2. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, The photovoltaic charging device is a crystalline silicon photovoltaic cell or a thin-film photovoltaic cell, and the panel transmittance of the crystalline silicon photovoltaic cell or the thin-film photovoltaic cell is 20% to 40%; the LED light-emitting device is a transparent flexible printed circuit board, and an LED lamp bead array is welded on the upper surface of the transparent flexible printed circuit board.

3. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, The first encapsulating layer, the second encapsulating layer, and the third encapsulating layer are each independently selected from polyvinyl butyral film, ethylene-vinyl acetate copolymer film, or ionic intermediate film film; the single-layer thickness of the first encapsulating layer, the second encapsulating layer, and the third encapsulating layer is each independently between 0.38 mm and 1.52 mm.

4. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, The front transparent glass layer is an ultra-clear tempered glass panel, and the rear glass layer is a tempered glass panel or a laminated safety glass panel; the thickness of each single layer of the front transparent glass layer and the rear glass layer is independently 5mm to 12mm.

5. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, A miniature electrolytic capacitor and a DC voltage regulator module are connected in series on the conductive cable between the photovoltaic charging device and the LED light-emitting device; the miniature electrolytic capacitor and the DC voltage regulator module are encapsulated inside the second encapsulation layer.

6. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 5, characterized in that, The nominal capacitance of the miniature electrolytic capacitor is 1000μF to 5000μF, and the output voltage of the DC voltage regulator module is 3.3V to 24V.

7. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, The vertical distance between the lower surface of the photovoltaic charging device and the upper surface of the LED light-emitting device is 0.38 mm to 1.52 mm; the parallelism error between the lower surface of the photovoltaic charging device and the upper surface of the LED light-emitting device is no greater than 0.5 mm.

8. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, The front transparent glass layer, the first encapsulating adhesive layer, the photovoltaic charging device, the second encapsulating adhesive layer, the LED light-emitting device, the third encapsulating adhesive layer, and the rear glass layer are integrally hot-pressed in a vacuum laminating furnace; the hot-pressing temperature of the vacuum laminating furnace is 120℃ to 140℃, the hot-pressing pressure is 1.0MPa to 1.2MPa, and the heat preservation and pressure holding time is 30 minutes to 40 minutes.

9. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, The overall transmittance of the laminate between the front transparent glass layer and the rear glass layer in the visible light band is 45% to 60%; the photoelectric conversion efficiency of the photovoltaic charging device under standard test conditions is not less than 15%; and the luminous uniformity of the LED light-emitting device under rated operating voltage is not less than 90%.

10. The laminated photovoltaic and LED composite optoelectronic integrated glass according to claim 1, characterized in that, The edges of the laminate formed by the front transparent glass layer, the first encapsulating adhesive layer, the photovoltaic charging device, the second encapsulating adhesive layer, the LED light-emitting device, the third encapsulating adhesive layer, and the rear glass layer are coated with butyl rubber sealing strips; the overall waterproof rating of the laminate reaches IP67, and there is no delamination or delamination phenomenon in the high and low temperature cycle test from -40℃ to 80℃.