阅读说明：本技术 玻璃前板及其制作方法 (Glass front plate and manufacturing method thereof ) 是由 李友情 王润 刘笑荣 徐小明 许厚旺 陈林 李晓东 唐法君 丁传标 于 2020-07-15 设计创作，主要内容包括：本申请属于光伏玻璃制作技术领域,尤其涉及一种玻璃前板及其制作方法,该玻璃前板制作方法包括以下步骤：将铯钾防火液均匀地喷涂于玻璃基板的相对两表面后,静置一段时间后清洗；再将玻璃基板放入钢化炉内进行钢化,钢化炉的加热时间为125s～145s,钢化炉的加热段沿玻璃基板输送方向分为进炉加热区、钢化加热区和出炉加热区,进炉加热区的加热温度设定为600℃～680℃,钢化加热区的加热温度设定为680℃～745℃,出炉加热区的加热温度设定为690℃～720℃,钢化炉内冷却段的冷却风压为28000pa～32000pa,冷却段的吹风距离为4mm～8mm,冷却段的出风温度为20℃～25℃；再在玻璃基板的表面镀设减反射膜层后固化,最终得到高应力、小碎片和高抗冲击强度的的玻璃前板。(The application belongs to the technical field of photovoltaic glass manufacturing, and particularly relates to a glass front plate and a manufacturing method thereof, wherein the manufacturing method of the glass front plate comprises the following steps: uniformly spraying the cesium potassium fire-proof liquid on two opposite surfaces of a glass substrate, standing for a period of time, and then cleaning; then placing the glass substrate into a toughening furnace for toughening, wherein the heating time of the toughening furnace is 125-145 s, the heating section of the toughening furnace is divided into a furnace entering heating zone, a toughening heating zone and a furnace exit heating zone along the conveying direction of the glass substrate, the heating temperature of the furnace entering heating zone is set to be 600-680 ℃, the heating temperature of the toughening heating zone is set to be 680-745 ℃, the heating temperature of the furnace exit heating zone is set to be 690-720 ℃, the cooling wind pressure of the cooling section in the toughening furnace is 28000-32000 pa, the blowing distance of the cooling section is 4-8 mm, and the air outlet temperature of the cooling section is 20-25 ℃; and plating an antireflection film layer on the surface of the glass substrate and then curing to finally obtain the glass front plate with high stress, small fragments and high impact strength.)

1. A method for manufacturing a glass front plate is characterized by comprising the following steps:

s10: providing raw materials: providing a glass substrate and a cesium potassium fire protection liquid;

s20: spraying: uniformly spraying the cesium potassium fire-retardant liquid on two opposite surfaces of the glass substrate, and standing for a period of time;

s30: cleaning: cleaning and standing the glass substrate;

s40: tempering: placing the cleaned glass substrate into a toughening furnace for toughening, wherein the heating time of the toughening furnace is 125-145 s, the heating section of the toughening furnace is divided into a furnace inlet heating zone, a toughening heating zone and a furnace outlet heating zone along the conveying direction of the glass substrate, the heating temperature of the furnace inlet heating zone is set to be 600-680 ℃, the heating temperature of the toughening heating zone is set to be 680-745 ℃, the heating temperature of the furnace outlet heating zone is set to be 690-720 ℃, the cooling air pressure of the cooling section in the toughening furnace is 28000-32000 pa, the air blowing distance of the cooling section is 4-8 mm, and the air outlet temperature of the cooling section is 20-25 ℃;

s50: film coating: plating an antireflection film layer on the surface of the tempered glass substrate;

s60: and (3) curing: and curing the coated glass substrate.

2. The method for manufacturing a glass front plate according to claim 1, characterized in that: the antireflection film layer is of a single-layer structure.

3. The method for manufacturing a glass front plate according to any one of claims 1 to 2, characterized in that: the step S20 specifically includes the following steps:

s21: pouring the cesium-potassium fireproof liquid into a sprinkling can;

s22: and uniformly spraying the cesium potassium fireproof liquid on the two opposite surfaces of the glass substrate by using the spray can.

4. The method for manufacturing a glass front plate according to any one of claims 1 to 2, characterized in that: in the step S20, the glass substrate is left to stand for 1 to 2 hours.

5. The method for manufacturing a glass front plate according to any one of claims 1 to 2, characterized in that: the heating time of the toughening furnace is 130-140 s.

6. The method for manufacturing a glass front plate according to any one of claims 1 to 2, characterized in that: the cooling wind pressure of the cooling section in the toughening furnace is 29000 pa-31000 pa.

7. The method for manufacturing a glass front plate according to any one of claims 1 to 2, characterized in that: the cooling air blowing distance is 4 mm-5 mm.

8. The method for manufacturing a glass front plate according to any one of claims 1 to 2, characterized in that: the air outlet temperature of the cooling section is 22-24 ℃.

9. The method for manufacturing a glass front plate according to any one of claims 1 to 2, characterized in that: between the step S10 and the step S20, the following steps are further included:

s11: cutting: cutting the glass substrate according to a preset size;

s12: edging: edging the cut glass substrate;

s13: cleaning: and cleaning the glass substrate after edging.

10. A glass front plate, characterized in that: the glass front plate is manufactured by the manufacturing method of the glass front plate as claimed in any one of claims 1 to 9.

Technical Field

The application belongs to the technical field of photovoltaic glass manufacturing, and particularly relates to a glass front plate and a manufacturing method thereof.

Background

The solar photovoltaic power generation technology is developed rapidly, the current market has higher and higher requirements on photovoltaic modules, and the requirements on the stress of glass front plates in the photovoltaic modules are higher and higher; the glass front plate adopted in the prior art is generally obtained by performing toughening treatment on a glass substrate through a toughening furnace, so that the stress performance of the glass substrate is improved, and then performing coating curing treatment on the surface of the glass substrate.

At present, a heating section of a toughening furnace is divided into three heating zones along the conveying direction of glass, namely a furnace inlet heating zone, a toughening heating zone and a furnace outlet heating zone; in the toughening process, the toughening heating time is 120-130 s, the temperature of a furnace entering heating zone is set to be 550-600 ℃, the temperature of a toughening heating zone is set to be 600-710 ℃, the temperature of a furnace exiting heating zone is set to be 685-700 ℃, the cooling air pressure of the toughening furnace is 24000-27000 pa, the air blowing distance of a cooling section is 8-12 mm, and the air outlet temperature of the cooling section is 40 ℃; however, the stress of the glass front plate obtained by the toughening process is generally within 60-100 Mpa, and fragments are located in 40-120 particles, so that the glass front plate has low stress and poor impact strength, and cannot meet the high stress requirement of the existing glass front plate.

Disclosure of Invention

The application aims to provide a glass front plate and a manufacturing method thereof, and aims to solve the technical problems of low stress and poor impact strength of the glass front plate in the prior art.

In order to achieve the purpose, the technical scheme adopted by the application is as follows: a glass front plate manufacturing method comprises the following steps:

s10: providing raw materials: providing a glass substrate and a cesium potassium fire protection liquid;

s20: spraying: uniformly spraying the cesium potassium fire-retardant liquid on two opposite surfaces of the glass substrate, and standing for a period of time;

s30: cleaning: cleaning and standing the glass substrate;

s40: tempering: placing the cleaned glass substrate into a toughening furnace for toughening, wherein the heating time of the toughening furnace is 125-145 s, the heating section of the toughening furnace is divided into a furnace inlet heating zone, a toughening heating zone and a furnace outlet heating zone along the conveying direction of the glass substrate, the heating temperature of the furnace inlet heating zone is set to be 600-680 ℃, the heating temperature of the toughening heating zone is set to be 680-745 ℃, the heating temperature of the furnace outlet heating zone is set to be 690-720 ℃, the cooling air pressure of the cooling section in the toughening furnace is 28000-32000 pa, the air blowing distance of the cooling section is 4-8 mm, and the air outlet temperature of the cooling section is 20-25 ℃;

s50: film coating: plating an antireflection film layer on the surface of the tempered glass substrate;

s60: and (3) curing: and curing the coated glass substrate.

Optionally, the antireflection film layer is of a single-layer structure.

Optionally, the step S20 specifically includes the following steps:

s21: pouring the cesium-potassium fireproof liquid into a sprinkling can;

s22: and uniformly spraying the cesium potassium fireproof liquid on the two opposite surfaces of the glass substrate by using the spray can.

Optionally, in the step S20, the glass substrate is left standing for 1 to 2 hours.

Optionally, the heating time of the toughening furnace is 130 s-140 s.

Optionally, the cooling air pressure of the cooling section in the toughening furnace is 29000pa to 31000 pa.

Optionally, the cooling air blowing distance is 4 mm-5 mm.

Optionally, the outlet air temperature of the cooling section is 22-24 ℃.

Optionally, between the step S10 and the step S20, the following steps are further included:

s11: cutting: cutting the glass substrate according to a preset size;

s12: edging: edging the cut glass substrate;

s13: cleaning: and cleaning the glass substrate after edging.

One or more technical schemes in the glass front plate manufacturing method provided by the application have at least one of the following technical effects: firstly, spraying cesium-potassium fireproof liquid on two opposite surfaces of a glass substrate, then standing for a period of time, wherein in the process, the cesium-potassium fireproof liquid is subjected to ion exchange with the surface of the glass substrate, and cesium ions or potassium ions in the cesium-potassium fireproof liquid replace sodium ions on the surface of the glass substrate to form low-expansion silicate glass, so that the stress and the impact strength of the glass substrate are greatly improved; then, cleaning and toughening the glass substrate, plating an antireflection film layer after toughening, and then curing the antireflection film layer to finally obtain the glass front plate, wherein compared with the toughening operation in the prior art, the toughening operation of the glass front plate manufacturing method improves the heating temperature, prolongs the heating time, promotes the cooling air pressure, reduces the blowing distance, and reduces the air outlet temperature of a cooling section, so that the glass substrate is firstly heated to a relatively high temperature, and the cooling speed of the glass substrate is accelerated, so that the glass substrate has a large tensile stress inside and generates a larger compressive stress on the surface of the glass substrate, thereby further improving the stress of the glass substrate and the impact strength of the glass; the manufacturing method of the glass front plate in the embodiment of the application mainly realizes high stress, small fragments and high impact strength of the glass front plate from two aspects of spraying cesium-potassium fireproof liquid and improving a tempering process, the stress of the glass front plate manufactured by the manufacturing method of the glass front plate is within 60-100 MPa, and the fragments are positioned between 100 particles and 120 particles.

Another technical scheme adopted by the application is as follows: a glass front plate is manufactured by adopting the manufacturing method of the glass front plate.

The glass front plate is prepared by adopting the glass front plate preparation method, the cesium potassium fireproof liquid is sprayed in the preparation process of the glass front plate, the heating temperature and the heating time are increased, and the cesium potassium fireproof liquid is rapidly cooled to improve two aspects of a tempering process, so that high stress, small fragments and high impact strength of the glass front plate are realized, the stress of the finally obtained glass front plate is within 60-100 Mpa, and the fragments are between 100 and 120.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without inventive exercise.

Fig. 1 is a flowchart of a method for manufacturing a glass front plate according to an embodiment of the present disclosure.

Detailed Description

Reference will now be made in detail to embodiments of the present application, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to fig. 1 are exemplary and intended to be used for explaining the present application and should not be construed as limiting the present application.

In one embodiment of the present application, as shown in fig. 1, there is provided a method of manufacturing a glass front plate, comprising the steps of:

s10: providing raw materials: providing a glass substrate and a cesium potassium fire protection liquid;

s20: spraying: uniformly spraying the cesium potassium fire-retardant liquid on two opposite surfaces of the glass substrate, and standing for a period of time;

s30: cleaning: cleaning and standing the glass substrate;

s40: tempering: placing the cleaned glass substrate into a toughening furnace for toughening, wherein the heating time of the toughening furnace is 125-145 s, the specific heating time can be 125s, 127s, 129s, 131s, 133s, 135s, 137s, 139s, 141s, 143s or 145s, the heating time mainly refers to the time from the glass substrate entering a heating section of the toughening furnace to the glass substrate exiting the heating section, the heating time is longer than that of the existing toughening process, and the conveying speed of the glass substrate is reduced mainly by reducing the rotating speed of conveying rollers in the toughening furnace, so that the purpose of greatly increasing the heating time is achieved;

furthermore, the heating section of the toughening furnace is divided into a furnace inlet heating zone, a toughening heating zone and a furnace outlet heating zone along the conveying direction of the glass substrate, and the glass substrate sequentially enters three heating zones of the heating section of the toughening furnace, namely the furnace inlet heating zone, the toughening heating zone and the furnace outlet heating zone;

further, the heating temperature of the furnace-entering heating zone is set to be 600 ℃ to 680 ℃, which specifically means that the heating temperature of the furnace-entering heating zone is gradually increased in the conveying direction of the glass substrate, namely, the heating temperature is gradually increased from 600 ℃ to 680 ℃, so that the temperature of the glass substrate is gradually increased from 600 ℃ to 680 ℃ in the furnace-entering heating zone, and the temperature of the glass substrate is gradually increased, thereby avoiding the damage of the glass substrate; the temperature of the heating section of the annealing furnace is set to be 600 ℃, if the temperature is too high, the glass substrate is easy to bend and curl, and if the temperature is too low, the heating section of the annealing furnace is too long, so that the production efficiency is seriously influenced.

Furthermore, the heating temperature of the toughening heating zone is set to be 680-745 ℃, which specifically means that the heating temperature of the toughening heating zone is gradually increased and then decreased in the conveying direction of the glass substrate, namely, the heating temperature is gradually increased from 680 ℃ to 745 ℃, and then is gradually decreased from 745 ℃ to 720 ℃, so that the temperature of the glass substrate is gradually increased from 600 ℃ to 680 ℃ after passing through the furnace entering heating zone, and then the temperature of the glass substrate is gradually increased from 680 ℃ to 745 ℃ and then is gradually decreased from 745 ℃ to 720 ℃ in the toughening heating zone, so that the glass substrate is buffered in the furnace entering heating zone when entering the high temperature toughening heating zone, and the glass is prevented from directly entering the high temperature toughening heating zone and being damaged due to the overhigh heating temperature;

furthermore, the heating temperature of the discharging heating zone is set to be 690-720 ℃, which specifically means that the heating temperature of the discharging heating zone is gradually reduced in the conveying direction of the glass substrate, namely gradually reduced from 720 ℃ to 690 ℃, and the temperature of the glass substrate is reduced after passing through the discharging heating zone, so that the temperature of the glass substrate entering the cooling section is relatively low, and the damage of the glass substrate due to overlarge temperature difference can be avoided.

Furthermore, the cooling wind pressure range of the cooling section in the toughening furnace is set to 28000 pa-32000 pa, wherein the specific cooling wind pressure can be set to 28000pa, 28500pa, 29000pa, 29500pa, 30000pa, 30500pa, 31000pa, 31500pa or 32000pa, and the cooling wind pressure is set in the range, so that the cooling wind pressure can be adjusted according to the change of seasons, and better performance of the glass substrate after cooling can be ensured, for example: in winter, the temperature is lower, and the cooling wind pressure can be properly reduced, for example, the cooling wind pressure is adjusted to 28000pa, so that the glass substrate is prevented from being too cold to obtain better strength; in summer, the temperature is higher, and at this moment, the glass substrate cooling needs bigger cooling wind pressure to guarantee that the glass substrate obtains good cooling, and good structural strength, for example with cooling wind pressure adjustment to 32000 pa.

Furthermore, the blowing distance range of the cooling section is set to be 4-8 mm, wherein the specific blowing distance can be set to be 4mm, 4.5mm, 5mm, 5.5mm, 6mm, 6.5mm, 7mm, 7.5mm or 8mm, and the blowing distance is set in the range, so that the blowing distance is adjusted according to the flatness and the curvature of the glass substrate in the specific production process, and the flatness and the curvature of the glass substrate are conveniently controlled to ensure that the obtained glass front plate meets the design requirement;

furthermore, the air outlet temperature of the cooling section is 20-25 ℃, wherein the air outlet temperature of the cooling section specifically refers to the air outlet temperature of the cooling section, the specific air outlet temperature is set to be 20 ℃, 21 ℃, 22 ℃, 23 ℃, 24 ℃ or 25 ℃, and the air outlet temperature is not greatly different from the daily environment temperature, so that the air outlet is simply heated or cooled, and the production energy consumption of the toughening furnace can be reduced.

Further, S50: film coating: plating an antireflection film layer on the surface of the tempered glass substrate; specifically, after the glass substrate is tempered, the surface of the glass substrate is plated with an antireflection film layer, and the transmittance of the glass front plate can be greatly improved through the antireflection film layer, so that the power generation efficiency of the photovoltaic module is greatly improved.

Further, S60: and (3) curing: and curing the coated glass substrate. Specifically, after the antireflection film layer is subjected to curing treatment, the antireflection film layer is cured and adhered to the glass substrate, so that the antireflection film layer and the glass substrate are more firmly bonded.

According to the manufacturing method of the glass front plate, firstly, cesium-potassium fireproof liquid is sprayed on two opposite surfaces of a glass substrate, then the glass front plate is placed for a period of time, in the process, the cesium-potassium fireproof liquid is subjected to ion exchange with the surface of the glass substrate, and cesium ions or potassium ions in the cesium-potassium fireproof liquid replace sodium ions on the surface of the glass substrate to form low-expansion silicate glass, so that the stress and the impact strength of the glass substrate are greatly improved; then, cleaning and toughening the glass substrate, plating an antireflection film layer after toughening, and then curing the antireflection film layer to finally obtain the glass front plate, wherein compared with the toughening operation in the prior art, the toughening operation of the glass front plate manufacturing method improves the heating temperature, prolongs the heating time, promotes the cooling air pressure, reduces the blowing distance, and reduces the air outlet temperature of a cooling section, so that the glass substrate is firstly heated to a relatively high temperature, and the cooling speed of the glass substrate is accelerated, so that the glass substrate has a large tensile stress inside and generates a larger compressive stress on the surface of the glass substrate, thereby further improving the stress of the glass substrate and the impact strength of the glass; the manufacturing method of the glass front plate provided by the embodiment of the application mainly realizes high stress, small fragments and high impact strength of the glass front plate from two aspects of spraying cesium-potassium fireproof liquid and improving a toughening process, the stress of the glass front plate manufactured by the manufacturing method of the glass front plate is within 60-100 Mpa, and the fragments are located between 100 particles and 120 particles.

In another embodiment of the present application, the antireflection film layer of the glass front plate is provided as a single layer structure. The antireflection film layer is of a single-layer structure, namely, only one antireflection film layer is plated on the surface of the glass substrate, and the film layer is simple in structure and convenient to manufacture.

In another embodiment of the present application, the antireflection film layer of the glass front plate is provided as a porous silica film layer. Specifically, holes are formed in the porous silicon dioxide film layer, and light can directly irradiate the glass substrate through the holes, so that the anti-reflection effect is achieved, and the transmittance of the anti-reflection coated glass is increased.

In another embodiment of the present application, the step S20 of the method for manufacturing a glass front plate specifically includes the following steps:

s21: pouring the cesium-potassium fireproof liquid into a sprinkling can;

s22: and uniformly spraying the cesium potassium fireproof liquid on the two opposite surfaces of the glass substrate by using the spray can.

Specifically, in the operation of spraying the cesium-potassium fireproof liquid, the cesium-potassium fireproof liquid is firstly poured into a spraying pot, and the cesium-potassium fireproof liquid is uniformly sprayed on the surface of the glass substrate by pressing the spraying pot, so that the spraying operation is simple, convenient and fast, the spraying uniformity of the spraying pot is good, and the stress and the structural strength of the glass substrate are also convenient to improve.

In another embodiment of the present application, in the method for manufacturing a glass front plate, in the step S20, the glass substrate is left standing for 1h to 2 h.

Specifically, after the cesium potassium fire-retardant liquid is sprayed, the cesium potassium fire-retardant liquid needs to be kept still for 1 to 2 hours, so that the cesium potassium fire-retardant liquid can fully react with the surface of the glass substrate, so that sodium ions on the surface of the glass are completely replaced, and the surface of the glass substrate has better strength and stress; the specific standing time can be 1h, 1.2h, 1.4h, 1.6h, 1.8h or 2h, and the standing time is set within the range of 1h to 2h, so that the cesium potassium fireproof liquid can be ensured to be fully reacted with the surface of the glass substrate, and the influence on the production efficiency due to overlong standing time can be avoided.

In another embodiment of the present application, there is provided the method for manufacturing a glass front plate, wherein the heating time of the tempering furnace is 130s to 140 s.

Specifically, the heating time of the tempering furnace may be 130s, 131s, 132s, 133s, 134s, 135s, 136s, 137s, 138s, 139s, or 140s, and the heating time is set within this time range, so that the glass front plate can be sufficiently heated and sufficiently tempered, thereby obtaining good strength and stress.

In another embodiment of the present application, there is provided a method for manufacturing a glass front plate, wherein the cooling wind pressure of the cooling section in the tempering furnace is 29000pa to 31000 pa. Specifically, the cooling wind pressure can be set to 29000pa, 29200pa, 29400pa, 29600pa, 29800pa, 30000pa, 30200pa, 30400pa, 30600pa, 30800pa or 31000pa, and the cooling wind pressure is set to be within the above range, so that the daily production requirement of the glass front plate can be met, and the too low or too high setting of the cooling wind pressure can be avoided, so that the glass substrate cannot be effectively cooled or the cooling speed is too high, and the stress and strength of the final glass front plate are affected.

In another embodiment of the present application, there is provided the method for manufacturing a glass front plate, wherein the cooling air blowing distance is 4mm to 5 mm. The blowing distance is usually set to be between 4mm and 5mm, so that the production requirements of most types of glass front plates can be met, if the blowing distance is set to be too small, the blowing distance is short, the cooling speed of the glass substrate is high, and the glass front plate is easy to damage; if the blowing distance is too long, the blowing distance is long, the cooling speed of the glass substrate is low, and the stress of the glass substrate cannot be effectively improved. Of course, in the actual production process, the air blowing distance of 1mm to 2mm can be adjusted up and down, so that the flatness and the bending degree of the glass can be adjusted. Specifically, the blowing distance of the cooling may be set to 4.1mm, 4.2mm, 4.3mm, 4.4mm, 4.5mm, 4.6mm, 4.7mm, 4.8mm, 4.9mm, or 5 mm.

In another embodiment of the present application, the air outlet temperature of the cooling section of the method for manufacturing the glass front plate is 22 ℃ to 24 ℃.

Specifically, the outlet air temperature of the cooling section is set to be 22 ℃, 22.5 ℃, 23 ℃, 23.5 ℃ or 24 ℃, the outlet air temperature of the cooling section is set in the range, the outlet air temperature of the cooling section is lower, and the cooling speed of the glass substrate is higher, so that the stress and the strength of the glass substrate are effectively improved.

In another embodiment of the present application, the method for manufacturing a glass front plate, between the step S10 and the step S20, further includes the steps of:

s11: cutting: cutting the glass substrate according to a preset size;

s12: edging: edging the cut glass substrate;

s13: cleaning: and cleaning the glass substrate after edging.

Specifically, before spraying, the glass substrate needs to be cut according to a preset size to meet the requirements of glass front plate products of different models, then the edge of the glass substrate is ground to avoid the level of edge explosion and corner explosion, and in the actual production process, the edge grinding needs to reach the accurate grinding level; after the edge grinding of the glass substrate is finished, the glass substrate is cleaned, and impurities such as dust on the surface of the glass substrate are cleaned, so that the subsequent cesium potassium fireproof liquid can be uniformly distributed on the surface of the glass substrate, sodium ions on the whole surface of the glass substrate are completely replaced, and the glass substrate is ensured to have the performances of high stress and small fragments.

In another embodiment of the present application, a glass front plate is provided, which is manufactured by the above glass front plate manufacturing method.

The glass front plate is manufactured by the manufacturing method of the glass front plate, the cesium potassium fireproof liquid is mainly sprayed in the manufacturing process of the glass front plate, the heating temperature and the heating time are increased, and the heating process is rapidly cooled to improve two aspects of a tempering process, so that high stress, small fragments and high impact strength of the glass front plate are realized, the stress of the finally obtained glass front plate is within 60-100 Mpa, and the fragments are located between 100 particles and 120 particles.

The above description is only exemplary of the present application and should not be taken as limiting the present application, as any modification, equivalent replacement, or improvement made within the spirit and principle of the present application should be included in the protection scope of the present application.