Borosilicate Glass Solar Modules for Thermal Shock Resistance
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Solution Overview
Problem
Conventional soda-lime glass plies used in automotive laminates are susceptible to thermal shock and cracking from impacts, necessitating improved glass compositions for thicker outer plies that enhance durability and impact resistance.
Innovation Solution
A borosilicate glass composition with a high SiO2, B2O3, and Al2O3 content, capable of fusion forming at high viscosities, is used to create glass plies that resist thermal shock and cracking, suitable for use as outer plies in laminates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If soda-lime glass is used for thicker outer glass plies, then the glass provides basic optical clarity and durability, but it is susceptible to thermal shock and cracking upon impact
Solution Approach 1:
The patent changes the chemical composition parameters of the glass by incorporating specific amounts of boron oxide (10-20 wt%), aluminum oxide (5-15 wt%), and silicon dioxide (60-75 wt%), along with controlled levels of alkali and alkaline earth oxides. This compositional parameter change transforms the glass properties to achieve both high strength and reliability against thermal shock and cracking
Solution Approach 2:
The patent creates a composite glass material by combining multiple oxide components in specific proportions. The borosilicate glass system integrates boron oxide, aluminum oxide, and silicon dioxide to form a composite structure that provides enhanced mechanical strength and thermal stability compared to conventional soda-lime glass
2Strength
If the outer glass ply is made thicker to improve impact performance, then fuel economy and impact resistance are improved, but the glass becomes more susceptible to thermal shock and cracking
Solution Approach 1:
The patent modifies the glass composition parameters to include boron oxide (10-20 wt%) and aluminum oxide (5-15 wt%) in the thicker glass ply formulation. These compositional changes enable the thicker glass to maintain high impact performance while simultaneously resisting thermal shock and cracking that would otherwise affect thicker conventional glass
3Reliability
If a borosilicate glass composition with high SiO2, B2O3, and Al2O3 content is used, then resistance to thermal shock and impact-induced cracking is enhanced, but the glass requires specific viscosity characteristics for fusion forming
Solution Approach 1:
The patent carefully balances the compositional parameters to achieve both high reliability and manufacturability. The boron oxide content (10-20 wt%) and aluminum oxide content (5-15 wt%) are optimized to provide thermal shock and crack resistance while maintaining liquidus viscosity between 300-800 kP and T200P between 1600-1750°C, which are suitable for fusion forming processes
Solution Approach 2:
The patent utilizes the phase transition characteristics of the borosilicate glass composition during heating and cooling. The specific compositional range ensures appropriate viscosity behavior during the melting and forming phases, allowing the glass to be successfully fusion formed while maintaining the desired high reliability properties in the final product
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The borosilicate glass plies demonstrate enhanced resistance to thermal shock and impact-induced cracking, maintaining structural integrity and performance in automotive glazing applications.
Implementation Method 1
the borosilicate glass plies demonstrate enhanced resistance to thermal shock and impact-induced cracking
Implementation Method 2
the borosilicate glass plies demonstrate enhanced resistance to thermal shock and impact-induced cracking
Data Source
AI summary
Various aspects of solar modules are set forth herein, at least one solar cell having a configured between a first substrate and a second substrate with an encapsulant configured between the first substrate and the second substate to retain the solar cell in place between the first substrate and the second substrate; wherein at least one of the first substrate and the second substrate is a borosilicate glass composition, comprising: at least 75 mol % SiO2; at least 10 mol % B2O3; and Al2O3 in an amount such that sum of SiO2, B2O3, and Al2O3 is at least 90 mol %.