ES2360455T3 - Procedimiento para fabricar módulos solares mediante un método de laminación por rodillos. - Google Patents

Procedimiento para fabricar módulos solares mediante un método de laminación por rodillos. Download PDF

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Publication number
ES2360455T3
ES2360455T3 ES08100857T ES08100857T ES2360455T3 ES 2360455 T3 ES2360455 T3 ES 2360455T3 ES 08100857 T ES08100857 T ES 08100857T ES 08100857 T ES08100857 T ES 08100857T ES 2360455 T3 ES2360455 T3 ES 2360455T3
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Prior art keywords
solar module
module according
temperature
manufacturing
manufacture
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ES08100857T
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English (en)
Inventor
Bernhard Dr. Koll
Andreas Karpinski
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Kuraray Europe GmbH
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Kuraray Europe GmbH
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Classifications

    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F71/00—Manufacture or treatment of devices covered by this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
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    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91441—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time
    • B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
    • B29C66/91445—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile by steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/9292—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10165—Functional features of the laminated safety glass or glazing
    • B32B17/10247—Laminated safety glass or glazing containing decorations or patterns for aesthetic reasons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
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    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
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    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
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    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Photovoltaic Devices (AREA)
  • Joining Of Glass To Other Materials (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

Procedimiento para la fabricación de un módulo solar a través de laminación de un cuerpo de capas que está constituido por un primer soporte (T1), sobre el que se aplica al menos una unidad de células solares (2) y un segundo soporte (T2) formado por al menos una lámina (F) intercalada, a base de polivinilacetal que contiene plastificante, caracterizado por calentamiento del cuerpo de capas en al menos un túnel caliente a una temperatura de 50 a 150ºC y prensado siguiente entre al menos una pareja de rodillos.

Description

Campo técnico
La invención se refiere a la fabricación de módulos solares de capa fina en el procedimiento compuesto de 5 laminación utilizando una lámina a base de polivinilbutiral (PVB).
Estado de la técnica
Los módulos solares de capa fina están constituidos, en general, por una capa de semiconductores fotosensibles (designada en adelante como unidad de células solares), que está aplicada sobre una placa la mayoría de las veces transparente, por ejemplo a través de evaporación, separación de fases de gases, pulverización catódica o
10 separación en húmedo y que se proveen para la protección contra influencias externas con una cubierta, dado el caso, igualmente transparente. Las unidades de células solares se laminan con frecuencia entre una hoja de vidrio y una placa de cubierta, por ejemplo de vidrio, con la ayuda de un adhesivo opcional transparente. El adhesivo debe rodear totalmente las unidades de células solares, debe ser estable a luz UV y debe estar totalmente libre de burbujas después del proceso de laminación.
15 Como adhesivo transparente se emplean con frecuencia resinas fundidas endurecibles o sistemas reticulables, a base de etileno vinil acetato (EVA), tal como se publica, por ejemplo, en los documentos DE 41 22 721 C1 o DE 41 28 766 A1. Estos sistemas adhesivos se pueden ajustar en el estado no endurecido de forma viscosa tan baja que cubren las unidades de células solares sin burbujas. Después de la adición de un endurecedor o agente reticulante se obtiene una capa adhesiva de alta resistencia mecánica. En tales módulos solares es un inconveniente su
20 fabricación costosa; especialmente en elementos de fachada de superficie grande, la incrustación de las unidades de células solares en la resina fundida líquida y su endurecimiento controlado es un proceso difícil de controlar. Además, algunas resinas fundidas tienden después de algunos años a la formación de burbujas o bien a delaminación.
Una alternativa a los sistemas adhesivos que se endurecen es el empleo de láminas a base de polivinilbutiral (PVB).
25 Aquí se cubren las unidades de células solares con una o varias láminas de PVB y éstas se conectan a presión elevada y a temperatura elevada con los materiales de cubierta deseados para formar un laminado. Se conocen procedimientos para la fabricación de módulos solares con la ayuda de láminas de PVB, por ejemplo, a través de los documentos DE 40 26 165 C2, DE 42 278 60 A1, DE 29 237 70 C2, DE 38 986 C2, DE 197 32 217, DE 40 26 165, US 6.160.215, WO 02/103809, US 6.660.556, US 2005/0115667 o US 4.321.418. En estas publicaciones, la lámina
30 de PVB sirve para la incrustación de unidades de células solares cristalinas; no se describen sistemas de una capa para módulos solares de capa fina o bien los procedimientos de fabricación adecuados para ello.
La utilización de láminas de PVB en módulos solares como acristalamientos compuestos se publica, por ejemplo, en los documentos DE 20 302 045 U1, EP 1617487 A1, y DE 35 389 86 C2. Estas publicaciones se refieren igualmente al encapsulamiento de células solares entre dos láminas de PVB.
35 En módulos solares de capa fina, las células solares están aplicadas directamente sobre un soporte como una hoja de vidrio o un soporte flexible de polímero o de metales. De acuerdo con la estructura en el soporte, no es posible un encapsulamiento de las células solares. Además, se pueden fabricar módulos solares de capa fina en tamaño discrecional y en grandes cantidades. Los procedimientos conocidos para la fabricación de módulos solares, que presentan células solares incrustadas entre láminas de PVB, no se pueden automatizar en una medida suficiente
40 para la fabricación de un compuesto con módulos solares de capa fina a escala industrial.
Además, los documentos DS 35 38 986 C2 y DE 42 27 860 publican la fabricación de módulos solares a través de un proceso de laminación a temperatura elevada y a presión elevada. No se describe la utilización de una pareja de rodillos para esta finalidad.
Se conoce a partir del documento US 2002/0038663 fabricar módulos de células solares por medio de un proceso
45 de laminación, utilizando células solares con formas redondeadas para la prevención de la penetración de las láminas adhesivas.
Problema
El problema de la presente invención es preparar un procedimiento para la fabricación de módulos solares de capa fina utilizando láminas intermedias termoplásticas, que posibilita una producción continua y/o automatizable.
50 Sorprendentemente se ha encontrado que un proceso de laminación con una pareja de rodillos es adecuado para la laminación también de células solares inestables mecánicamente.
Representación de la invención Por lo tanto, un objeto de la presente invención es un procedimiento para la fabricación de un módulo solar a través de laminación de un cuerpo de capas que está constituido por un primer soporte, sobre el que se aplica al menos una unidad de células solares y un segundo soporte formado por al menos una lámina intercalada, a base de polivinilacetal que contiene plastificante, a través de calentamiento del cuerpo de capas en al menos un túnel
5 caliente y prensado siguiente a una temperatura de 50 a 150ºC, en particular de 60 a 150ºC entre al menos una pareja de rodillos.
Con preferencia, en las prensas se aplican presiones lineales de 0,5 N/mm a 100 N/mm, en particular de 10 N/mm a 50 N/mm. Por presión lineal se entiende la presión de prensado de una pareja de rodillos con relación a la anchura de la lámina.
10 Para la prevención de destrucciones en las placas de cubierta se puede reducir en el canto delantero y en el canto trasero del cuerpo de capas (al comienzo y al final del laminado) la presión lineal hasta el peso propio de los rodillos superiores de prensado o a través de la elevación de los rodillos superiores de prensado hasta cero.
Adicionalmente, en puntos de interferencia en el cuerpo de capas, como por ejemplo contactos eléctricos o bandas de conductores puede ser necesario reducir la velocidad de transporte del cuerpo de capas a través de la prensa de
15 rodillos, para conseguir una duración de actuación elevada de la presión lineal. De esta manera se consigue una ventilación y un encolado mejorados del punto de interferencia con el polivinilacetal.
La figura 1 muestra la estructura esquemática de una instalación adecuada con dos parejas de rodillos.
El procedimiento de acuerdo con la invención se realiza utilizando una o varias, con preferencia dos prensas, que están constituidas, respectivamente, por una pareja de rodillos de prensa. En este caso, el cuerpo de capas es
20 prensado entre al menos una pareja de rodillos con la misma o diferente presión lineal y con la misma o diferente temperatura.
Se conocen instalaciones de este tipo para la fabricación de acristalamientos compuestos y disponen normalmente de al menos un túnel de calor para la elevación u homogeneización de la temperatura antes o bien después de la primera prensa en instalaciones con dos prensas. También es concebible el procesamiento en instalaciones que
25 disponen de al menos un túnel de calor alojado a continuación de la última prensa para la elevación u homogeneización de la temperatura, o en instalaciones que están equipadas con más de dos prensas con túneles de calor antepuestos, respectivamente.
Las temperaturas mencionadas se refieren al menos a un cuerpo de capas delante de la última pareja de rodillos a recorrer.
30 Opcionalmente es posible crear delante de la última pareja de rodillos otras parejas de rodillos con o sin zona de calor antepuesta, de manera que el cuerpo de capas puede presentar aquí las temperaturas mencionadas o también temperaturas más bajas que 50ºC o 60ºC.
En el procedimiento de acuerdo con la invención, los cuerpos de capas son calentados antes del prensado en túneles de calor, por ejemplo con radiación IR, radiación de microondas o por convección a temperaturas de50ºC ó
35 60ºC hasta 150ºC, respectivamente, con preferencia 70ºC u 80ºC a 100ºC, respectivamente. La temperatura de los compuestos se puede medir, por ejemplo, sin contacto a través de un pirómetro de radiación.
La lámina a base de polivinilacetal que contiene plastificante contiene con preferencia polivinilbutiral (PVB) no reticulado, que se obtiene a través de acetalización de alcohol de polivinilo con butilaldehído.
De la misma manera es posible el empleo de polivinilacetales reticulados, en particular de polivinilbutiral (PVB)
40 reticulado. Polivinilacetales articulados adecuados se describen, por ejemplo, en los documentos EP 1 527 107 B1 y WO 2004/063231 A1 (auto-reticulación térmica de polivinilacetales que contienen grupos carboxilo), EP 1 606 325 A1 (polivinilacetales reticulados con polialdehídos) y WO 03/020776 A1 (polivinilacetales reticulados con ácido glioxílico).
También es posible realizar la acetalización con otros aldehídos, por ejemplo con aquéllos que tienen de 5 a 10 45 átomos de carbono, como por ejemplo valeraldehído.
Los alcoholes de polivinilo necesarios para la fabricación de polivinilacetales pueden ser, en el marco de la presente invención, también terpolímeros a partir de copolímeros de acetato de vinilo / etileno. Estos compuestos están hidrolizados, en general, hasta más del 98 % y contienen de 1 a 10 unidades en peso a base de etileno (por ejemplo, Tipo “Exceval” de la Kuraray Europe GmbH). La acetalización se puede realizar como para alcohol de
50 polivinilo.
Las láminas adecuadas a base de los polivinilacetales mencionados, en particular PVB, contienen además de 50-85 % en peso o de 50-80 % en peso de polivinilacetal, también de 50-15 % en peso de plastificante y cantidades reducidas de reguladores de la adhesión, agentes antibloqueo y estabilizadores UV. Las láminas de este tipo se designan a continuación de forma abreviada como láminas de PVB. La fabricación de principio y la composición de láminas de FVB para acristalamientos compuestos de seguridad se describe, por ejemplo, en los documentos EP 185 863 B1, EP 1 118 258 B1 o WO 02/102591 A1.
En una forma de realización especial de la presente invención, el módulo solar posee propiedades de aislamiento acústico, de manera que al menos una de las láminas presenta propiedades de aislamiento acústico. Las láminas de
5 aislamiento acústico a base de PVB se describen, por ejemplo, en los documentos EP 1 118 258 B1 o EP 387 148 B1. Las láminas de aislamiento acústico de acuerdo con el documento EP 1 118 258 B1 elevan el aislamiento acústico de un cristal compuesto de seguridad en su frecuencia de coincidencia en el intervalo de 1.000 a 3.500 Hz en al menos 2dB, medido según DIN EN ISO 717.
El espesor de las láminas a base de polivinilacetal que contiene plastificante se encuentra con preferencia en los 10 espesores habituales en la industria de estas láminas como 0,38, 0,51, 0,76, 1,14, 1,52 ó 2,28.
La lámina a base de polivinilacetal que contiene plastificante presenta con preferencia una estructura superficial aplicada por un lado o de manera especialmente preferida por los dos lados con una rugosidad de Rz > 35 µm yRz < 180 µm, especialmente con preferencia Rz > 70 µm y Rz < 130 µm y especialmente de Rz > 90 µm y Rz < 130 µm. Si la rugosidad superficial Rz es inferior a 35 µm, entonces se produce, a la temperatura necesaria para la inundación
15 de las bandas de conductores o de otras estructuras internas, un cierre precoz de los bordes del compuesto, antes de que el aire pueda ser expulsado totalmente. La consecuencia son inclusiones de aire (burbujas) en el centro del compuesto. En el caso de rugosidad superficial demasiado alta (Rz > 180 µm), se eleva la energía necesaria para la fundición de las puntas de rugosidad.
La estructura superficial de la lámina se puede generar a través del llamado procedimiento de rotura del flujo o de
20 rotura de la fundición inmediatamente antes de la salida de la colada de plástico desde la tobera de extrusión de acuerdo con el documento EP 0 185 863 B1. Se pueden generar de forma selectiva diferentes niveles de rugosidad a través de la variación de la anchura del intersticio de salida y de la temperatura de los labios de las toberas directamente en la salida de las toberas. Este procedimiento conduce a una rugosidad irregular, aproximadamente isótropa. El valor de medición de la rugosidad es aquí aproximadamente igual medido sobre todas las direcciones,
25 estando dispuestas, sin embargo, las elevaciones y las cavidades individuales de forma irregular en su altura y distribución.
De manera alternativa, la estructura superficial de la lámina se puede aplicar a través de procedimientos de estampación, por ejemplo según el documento EP 06112163 o EP 06112159. Aquí resulta una rugosidad o estructura de rugosidad regular.
30 La medición de la rugosidad superficial Rz o del valor de la rugosidad Rz se realiza según DIN EN ISO 4287. Las mediciones indicadas han sido realizadas con un aparato de medición de la rugosidad de la Fa. Mahr Tipo S2, aparato de avance PGK con pulsador mecánico de una fase MFW-250.
El cuerpo prensado se puede exponer a continuación a una presión elevada o reducida y a temperatura elevada, respectivamente. Esto se puede realizar de manera similar a los procedimientos conocidos de autoclaves, anillo de
35 vacío o bien bolsa de vacío, por ejemplo, según el documento EP 1 235 683 B1.
En el procedimiento de bolsa de vacío, el cuerpo de capas prensado es llevado a una bolsa de plástico o de goma. A continuación, esta bolsa es sellada de forma hermética al aire y es provista con una válvula de vacío con preferencia en el centro del disco. En el caso de cuerpos de formato grande, se pueden prever también dos válvulas de vacío. A través de una bomba de vacío se aplica en primer lugar un vacío inferior a 200 mbares y se evacua al menos 40 durante 5 minutos a temperatura ambiente. A continuación, manteniendo el vacío en un armario de circulación de aire se calienta el sándwich a 140ºC. La velocidad de calentamiento es en este caso de acuerdo con la potencia de calefacción de 4 a 6ºC/minuto, de manera que se alcanza la temperatura de mantenimiento de 140ºC después de 20 a 30 minutos. A continuación se mantiene la temperatura durante 30 minutos a 140ºC. Luego debe refrigerarse al menos º 60ºC, ates de que se pueda eliminar el vacío. En la práctica, el cuerpo prensado se expone a una presión
45 reducida de 0,01 a 300 mbares y a una temperatura de 100 a 200ºC.
De manera alternativa, se pueden realizar procesos de autoclaves. Éstos son conocidos por el técnico para la fabricación de acristalamientos compuestos y se realizan a una presión elevada de aproximadamente 7 a 15 bares y a temperaturas de 130 a 145ºC durante 10 a 120 minutos.
Las láminas que se pueden emplear de acuerdo con la invención deben cubrir o encerrar las unidades de células
50 solares o bien sus conexiones eléctricas sin burbujas y en unión por fricción; al mismo tiempo se requiere un espesor total lo más reducido posible de los módulos solares. A tal fin, es conveniente que las láminas “ablanden” en las condiciones de fabricación las unidades de células solares y sus conexiones eléctricas, es decir, que presenten una cierta fluencia en las condiciones de laminación.
La capacidad de adhesión de las láminas a base de polivinilacetales en cristal se puede ajustar a través de la
55 adición de reguladores de la adhesión como, por ejemplo, las sales alcalinas y/o alcalinotérreas de ácidos orgánicos publicadas, por ejemplo, en el documento WO 03/033583. Se han revelado como especialmente adecuados acetato potásico y/o acetato de magnesio. Para la obtención de valores de adhesión altos puede ser necesario emplear láminas sin adición de reguladores de la adhesión como sales alcalinas y/o sales alcalinotérreas.
El primero y/o el segundo soporte del módulo solar de acuerdo con la invención puede estar constituido de cristal, de plástico o de metal o de sus compuestos, debiendo ser transparente al menos uno de los soportes. De la misma
5 manera es posible realizar uno o los dos soportes como acristalamiento compuesto (es decir, como laminado de al menos dos hojas de cristal y al menos una lámina) o como acristalamiento aislante con un espacio intermedio de gas. Evidentemente, también es posible la combinación de estas medidas.
También es posible aplicar las unidades de células solares sobre un primer soporte, especialmente un soporte flexible y prensarlas entre dos capas de polivinilacetal que contiene plastificante y dos soportes con preferencia 10 transparentes. Las figuras 3 a 5 muestran, respectivamente una estructura esquemática de laminados fabricados de acuerdo con la invención, donde T1, T2 y T3 representan los materiales de soporte, F representa una lámina o capa de polivinilacetal que contiene plastificante, S representa las células solares y E representa el contacto eléctrico dado el caso necesario de las unidades solares individuales. En las figuras 3 y 4, las células solares o bien las capas fotoactivas están aplicadas sobre materiales de soporte, de manera que en la variante según la figura 4 se utiliza
15 con preferencia un soporte flexible T3.
Las células solares empleadas en los módulos solares no tienen que poseer propiedades especiales. Se pueden emplear sistemas de semiconductores cristalinos o amorfos, inorgánicos u orgánicos, que están aplicados sobre el primer soporte. Para proporcionar una tensión suficiente, se pueden conectar eléctricamente varias células solares entre sí. El espesor de las células solares, llamado en los módulos de capa fina también capa funcional, tiene al
20 menos 0,1 µm. El espesor de las bandas de conductores necesarias para la conexión eléctrica de las células solares está normalmente en > 50 µm.
La figura 2 muestra una estructura esquemática de un módulo solar, en la que S representa las células solares y P representa las bandas de conductores.
Los módulos solares fabricadas de acuerdo con la invención se pueden utilizar adicionalmente como componente de
25 fachada, superficies de techo, cubierta de invernadero, pared de aislamiento acústico, elemento de terraza o elemento de barandilla o como componente de superficies de ventana.
Ejemplo
Un módulo de capa fina del tamaño de 30 cm de largo x 20 cm de ancho con un espesor del cristal de 3,2 mm con dos bandas de conductores longitudinales, distanciadas en cada caso 20 mm del borde con una anchura de 2 mm y 30 un espesor de aproximadamente 250 µm fue prensado en una instalación de acuerdo con la figura 1 a una temperatura (después de la última prensa) de 90ºC y una presión lineal de 35 N/mm, respectivamente, y una velocidad de avance de 3 m/min. La dirección de avance del compuesto fue seleccionada de tal manera que la salida de las bandas de conductores desde el módulo estaba detrás y fue prensada en último lugar. Como lámina de polivinilacetal que contiene plastificante se empleó una lámina del tipo Trosifol HR 100 (Kuraray Europe GmbH) con
35 una rugosidad Rz de aproximadamente 100 µm.
La presión lineal de las prensas fue reducida sobre los primeros 10 mm y sobre los últimos 30 mm del cuerpo de capas sobre el peso propio de los rodillos superiores.
Se obtuvieron laminados libres de burbujas con una turbiedad reducida.
La turbiedad se pudo eliminar totalmente en un proceso de autoclave siguiente a 140ºC y 12 bares con un tiempo de 40 retención de 30 minutos.
En lugar del proceso de autoclave se puede eliminar la turbiedad también en un proceso de vacío a 145ºC y 150 mbares con un tiempo de retención de dos horas.
Por lo tanto, el procedimiento de acuerdo con la invención es adecuado para la fabricación de módulos solares, opcionalmente se puede eliminar una turbiedad a través de una etapa del procedimiento conectada a continuación.
45

Claims (7)

  1. REIVINDICACIONES
    1. Procedimiento para la fabricación de un módulo solar a través de laminación de un cuerpo de capas que está constituido por un primer soporte (T1), sobre el que se aplica al menos una unidad de células solares (2) y un segundo soporte (T2) formado por al menos una lámina (F) intercalada, a base de polivinilacetal que contiene
    5 plastificante, caracterizado por calentamiento del cuerpo de capas en al menos un túnel caliente a una temperatura de 50 a 150ºC y prensado siguiente entre al menos una pareja de rodillos.
  2. 2.
    Procedimiento para la fabricación de un módulo solar de acuerdo con la reivindicación 1, caracterizado porque el prensado entre las parejas de rodillos se realiza a una presión lineal de 0,5 N/mm a 100 N/mm.
  3. 3.
    Procedimiento para la fabricación de un módulo solar de acuerdo con una de las reivindicaciones 1 ó 2,
    10 caracterizado porque el cuerpo de capas es prensado entre al menos dos parejas de rodillos con la misma o diferente presión lineal y con la misma o diferente temperatura.
  4. 4. Procedimiento para la fabricación de un módulo solar de acuerdo con una de las reivindicaciones 1 a 3, caracterizado porque la lámina, a base de polivinilacetal que contiene plastificante presenta un valor de rugosidad Rz unilateral o bilateral entre 35 µm y 180 µm.
    15 5. Procedimiento para la fabricación de un módulo solar de acuerdo con una de las reivindicaciones 1 a 4, caracterizado porque la lámina a base de polivinilacetal que contiene plastificante presenta una estructura de rugosidad regular.
  5. 6. Procedimiento para la fabricación de un módulo solar de acuerdo con una de las reivindicaciones 1 a 4,
    caracterizado porque la lámina (F) a base de polivinilacetal que contiene plastificante presenta una estructura de 20 rugosidad irregular.
  6. 7. Procedimiento para la fabricación de un módulo solar de acuerdo con una de las reivindicaciones 1 a 6, caracterizado porque el primero (T1) y/o el segundo soporte (T2) están constituidos de vidrio, plástico o sus compuestos, de un acristalamiento compuesto y/o de un acristalamiento aislante, con la salvedad de que al menos uno de los soportes (T1, T2) es transparente.
    25 8. Procedimiento para la fabricación de un módulo solar de acuerdo con una de las reivindicaciones 1 a 7, caracterizado porque el cuerpo prensado se expone a una presión elevada o reducida y a una temperatura reducida.
  7. 9. Procedimiento para la fabricación de un módulo solar de acuerdo con la reivindicación 8, caracterizado porque el cuerpo prensado se expone a una presión reducida de 0,01 a 200 mbares y a una temperatura de 100 a 200ºC.
    30 10. Procedimiento para la fabricación de un módulo solar de acuerdo con la reivindicación 8, caracterizado porque el cuerpo prensado se expone a una presión elevada de 7 a 15 bares y a una temperatura de 130 a 145ºC.
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DE102007005845A1 (de) 2008-08-07
EP1953829A1 (de) 2008-08-06
PL1953829T3 (pl) 2011-07-29
MX2008001137A (es) 2009-02-24
AU2007252454A1 (en) 2008-08-21
CN101237008B (zh) 2012-05-30
PT1953829E (pt) 2011-05-30
TW200849632A (en) 2008-12-16
DE502008002704D1 (de) 2011-04-14
US20080185096A1 (en) 2008-08-07
JP5692956B2 (ja) 2015-04-01
ZA200800539B (en) 2008-12-31
CN101237008A (zh) 2008-08-06
PL1953829T5 (pl) 2017-09-29
SG144812A1 (en) 2008-08-28
TWI485874B (zh) 2015-05-21
EP1953829B1 (de) 2011-03-02
JP2008193085A (ja) 2008-08-21
US8097117B2 (en) 2012-01-17
ATE500620T1 (de) 2011-03-15
BRPI0800226A (pt) 2008-09-16

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