CN112599624A - 一种体装式一体化柔性太阳电池阵及其制备方法 - Google Patents
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Abstract
本发明属于空间能源技术领域，涉及太阳电池阵制备方法，具体涉及一种体装式一体化柔性太阳电池阵及其制备方法，所述体装式一体化柔性太阳电池阵由上至下依次为高透光薄膜层5、胶结层4、薄膜太阳电池3、胶结层2、隔热多层反射层1、隔热多层间隔层6，在应用时，能够通过尼龙搭扣直接安装在飞行器表面，具有高效、轻质、柔性、可卷曲、适合异型曲面贴装等特点，且具有优异的空间环境适应性，在临近空间、低轨道空间环境飞行器领域具有良好应用前景。
Description
技术领域
本发明属于空间能源技术领域，涉及太阳电池阵制备方法，具体涉及一种体装式一体化柔性太阳电池阵及其制备方法。
背景技术
随着空间技术的发展，空间飞行器主要采用的太阳翼模式的太阳电池阵为平台供电，部分飞行器因特殊需求仍采用体装式太阳电池阵。相对于传统的体装式太阳电池阵，要求电池阵轻质柔性、可卷曲，现有的太阳电池阵无法满足其应用要求。薄膜太阳电池具有重量轻、可弯曲特点，但受限柔性太阳电池阵制备技术，导致空间应用缓慢。
为实现柔性太阳电池阵空间应用，近年来，国内外多家单位均开展了该方面的研究。专利201010191145.6超轻柔太阳电池阵及其制造方法，柔性薄膜太阳电池单体表面为高透过率透明封装层，位于薄膜电池单体下方的衬底层、加固层与隔热层，各层之间通过胶结层结合。专利201811357436.0一种空间用砷化镓薄膜太阳电池阵及其制备方法，在柔性基板表面涂覆液态硅橡胶，将薄膜太阳电池串铺设在对应未固化的硅橡胶表面，并进行大面积真空加压固化，在真空加压固化后的薄膜电池阵列区域表面涂覆液态透明硅橡胶，将柔性透明复合薄膜敷设在对应未固化的液态透明硅橡胶表面，并进行真空加压固化，完成柔性薄膜太阳电池阵的制备。上述的制备方式，将薄膜太阳电池胶接在衬底后，再在薄膜太阳电池表面胶接透明薄膜，再将该电池阵安装在飞行器表面。该制备过程工序较多，产品的可靠性难以保证。专利201410657303.0一种折叠展开式电池内置的柔性太阳电池阵，包括刚性衬底、柔性基板、正极集成电路、折叠区域、负极集成电路、裸露铜、叠层太阳电池、焊点、导线、正极输出端、负极输出端；所述叠层太阳电池固定安装在柔性基板上，在柔性基板的背面固定有刚性衬底，且在内部有正极集成电路和负极集成电路，正极集成电路、负极集成电路的输出端通过与引出导线、裸露铜与焊点焊接，经过柔性基板内部集成电路连接到正极输出端和负极输出端，实现电性能的输出；所述折叠展开式电池内置的柔性太阳电池阵上设有折叠区域，仅由柔性基板构成；所述折叠区域位于正面安装叠层太阳电池、背面固定有刚性衬底的柔性基板之间；该方法结构复杂。
专利申请号CN03141236.X太阳电池组件和太阳电池组件的安装方法，在太阳电池组件受光表面侧粘贴透明或半透明膜，并可以剥离去除。专利申请号201610630348.8公开了一种柔性大面积钙钛矿太阳电池组件及其制备方法。该钙钛矿太阳电池组件包括一依次层叠于柔性衬底之上的金属背反射层、电子传输层、钙钛矿吸收层、空穴传输层、透明导电前电极、透明封装胶、柔性透明塑料盖板，光由柔性透明塑料盖板方向入射；金属背反射层、电子传输层、钙钛矿吸收层、空穴传输层、透明导电前电极被预设的划槽隔开而形成多个相串联的子电池。上述专利表面粘贴膜及表面透明塑料盖板的作用为减少太阳电池组件制造期间表面的损伤及免受外界环境损伤，其并不适用于空间环境，不具有抗辐照功能。
针对上述的问题，本专利采用空间飞行器本身需要的隔热多层的反射层为衬底材料，然后将薄膜太阳电池一步封装在透明薄膜和衬底之间，最后集成在隔热多层的间隔层，使该柔性太阳电池阵集成有发电及隔热功能，相对上述专利无需引入基底，实现减重，工序简化，结构简单，重量更轻。
发明内容
为了解决现有技术中存在的上述技术问题，本发明提供一种体装式一体化柔性太阳电池阵及其制备方法，具体如下：
一种体装式一体化柔性太阳电池阵由上至下依次为高透光薄膜层5、胶结层4、薄膜太阳电池3、胶结层2、隔热多层反射层1、隔热多层间隔层6。
采用该结构具有以下优势：最上层的高透光薄膜5在满足高透光率的前提下，具有抗辐照性能，降低辐照导致的太阳电池性能衰减；利用底层的隔热反射层1、隔热多层间隔层6作为衬底，既保留了其隔热的功能，同时省去太阳电池阵的衬底层，实现结构功能一体化；胶结层4、胶结层2保证高透光薄膜层5与隔热多层反射层1与薄膜太阳电池3的有效结合。
本发明同时提供了体装式一体化柔性太阳电池阵的制备方法，包括如下步骤：
1)将薄膜太阳电池串并互连，得串并互连的薄膜太阳电池；
2)将高透光薄膜置于串并互连的薄膜太阳电池的上方，同时将隔热多层反射层置于串并互连的薄膜太阳电池下方；
3)采用热真空封装方法在压力为6×10-3Pa条件下将高透光薄膜、串并互连薄膜太阳电池、隔热多层反射层进行胶结，形成由上至下依次为高透光薄膜层、胶结层、薄膜太阳电池、胶结层、隔热多层反射层的结构，得薄膜太阳电池组件；
4)将薄膜太阳电池组件与隔热多层间隔层进行胶结，即得体装式一体化柔性太阳电池阵。
所述的薄膜太阳电池为非晶硅薄膜太阳电池、铜铟镓硒薄膜太阳电池、碲化镉薄膜太阳电池、砷化镓薄膜太阳电池中的任意一种。
所述的互连方式为锡焊、电阻焊、导电胶粘结中的任意一种。
所述的串联方式为互连片焊接串联或“叠瓦”式串联中的任意一种。
太阳电池阵为达到设计所需的输出电压，需要交太阳电池单体进行串联；为达到设计所需的输出电流，需要将太阳电池并联；上述连接方式为行业内通用成熟方式。
所述的高透光薄膜为含氟类聚合物薄膜。
所述的高透光薄膜为PTFE、FEP、PVDF、ETFE中的任意一种。
所述胶结采用的胶结剂为硅橡胶、EVA、环氧橡胶中的任意一种。
所述隔热多层反射层为聚酰亚胺底材，所述聚酰亚胺底材背面镀金、银或铝中的任意一种。
聚酰亚胺材料具有较好热阻性，绝缘性，为宇宙空间隔热多层反射层底材的指定材料；不同温度下的隔热要求选用不同镀层，镀铝成本较低。
与现有技术相比，本发明至少具有以下有益效果：
本发明采用真空封装技术将薄膜太阳电池直接封装在隔热多层的反射层与高透光薄膜之间，采用真空封装为避免操作时引入气泡，否则太阳电池阵进入宇宙空间后，在真空下该气泡会逐渐膨胀影响性能，有效省去了一层衬底材料，使得体装式一体化柔性太阳电池阵的重量轻，制备工序简化，可操作性强。
本发明的体装式一体化柔性太阳电池阵有效将柔性太阳电池阵与隔热多层集成一起，在应用时，能够通过尼龙搭扣直接安装在飞行器表面，具有高效、轻质、柔性、可卷曲、适合异型曲面贴装等特点，且具有优异的空间环境适应性，在临近空间、低轨道空间环境飞行器领域具有良好应用前景。
附图说明
下面结合附图对发明进一步说明：
图1为本发明提供的柔性太阳电池阵封装截面示意图(图中，5-高透光薄膜层、4-胶结层、3-薄膜太阳电池、2-胶结层、1-隔热多层反射层、6-隔热多层间隔层)；
图2为本发明提供的一种薄膜太阳电池互连片焊接串联示意图；
图3为本发明提供的一种薄膜太阳电池“叠瓦”式串联示意图。
具体实施方式
下面结合具体的实施方式来对本发明的技术方案做进一步的限定，但要求保护的范围不仅局限于所作的描述。
实施例1
体装式一体化柔性太阳电池阵的制备方法，包括如下步骤：
1)将非晶硅薄膜太阳电池3通过互联片锡焊的方式焊接互连；
2)在背面镀银的聚酰亚胺膜1表面均匀地涂覆硅橡胶2，将互连的非晶硅薄膜太阳电池3置于涂覆的硅橡胶区域；
3)在PTFE5表面均匀涂覆透明硅橡胶4，再将涂覆有硅橡胶的PTFE薄膜置于非晶硅薄膜太阳电池3表面，采用真空热封在压力为6×10-3Pa条件下使硅橡胶2、透明硅橡胶3固化，得封装的非晶硅薄膜太阳电池；
4)将封装的非晶硅薄膜太阳电池与隔热多层间隔层6胶结，制得到一体化柔性太阳电池阵。
实施例2
体装式一体化柔性太阳电池阵的制备方法，包括如下步骤：
1)将砷化镓薄膜太阳电池3通过互联片电阻焊的方式焊接互连；
2)在背面镀铝的聚酰亚胺膜1表面均匀地涂覆硅橡胶2，将互连的砷化镓薄膜太阳电池3置于涂覆的硅橡胶区域；
3)在ETFE5表面均匀涂覆透明硅橡胶4，再将涂覆有硅橡胶的ETFE薄膜置于砷化镓薄膜太阳电池3表面，采用真空热封在压力为6×10-3Pa条件下使硅橡胶2、透明硅橡胶3固化，得封装的薄膜太阳电池；
4)将封装的薄膜太阳电池与隔热多层间隔层6胶结在一起，制备得到一体化柔性太阳电池阵。
实施例3
体装式一体化柔性太阳电池阵的制备方法，包括如下步骤：
1)将铜铟镓硒薄膜太阳电池3通过叠瓦导电胶的方式粘结互连；
2)在背面镀金的聚酰亚胺膜1表面均匀地涂覆EVA胶2，将互连的铜铟镓硒薄膜太阳电池3置于涂覆的EVA胶区域；
3)在PVDF5表面均匀涂覆透明硅橡胶4，再将涂覆有硅橡胶的PVDF薄膜置于铜铟镓硒太阳电池3表面，采用真空热封在压力为6×10-3Pa条件下使EVA胶2、透明硅橡胶3固化，得封装的铜铟镓硒薄膜太阳电池；
4)将封装的铜铟镓硒薄膜太阳电池与隔热多层间隔层6胶结在一起，制备得到一体化柔性太阳电池阵。
实施例4
1)将碲化镉薄膜太阳电池3通过互连片锡焊的方式焊接互连；
2)在背面镀铝的聚酰亚胺膜1表面均匀地涂覆环氧橡胶2，将互连的碲化镉薄膜太阳电池3置于涂覆的环氧橡胶区域；
3)在FEP5表面均匀涂覆透明硅橡胶4，再将涂覆有硅橡胶的FEP薄膜置于碲化镉太阳电池3表面，采用真空热封使环氧橡胶2、透明硅橡胶3固化，得封装的碲化镉薄膜太阳电池；
4)将封装的碲化镉薄膜太阳电池与隔热多层间隔层6胶结在一起，制备得到一体化柔性太阳电池阵。
实施例5
一种体装式一体化柔性太阳电池阵由上至下依次为高透光薄膜层5、胶结层4、薄膜太阳电池3、胶结层2、隔热多层反射层1、隔热多层间隔层6；
所述的薄膜太阳电池为铜铟镓硒薄膜太阳电池；
所述的高透光薄膜层为PTFE；
所述胶结层为环氧橡胶；
所述隔热多层反射层为聚酰亚胺底材，所述聚酰亚胺底材背面镀铝。
对比例1
一种体装式一体化柔性太阳电池阵由上至下依次为胶结层、薄膜太阳电池、胶结层、隔热多层反射层、隔热多层间隔层；
所述的薄膜太阳电池为铜铟镓硒薄膜太阳电池；
所述的高透光薄膜层为PTFE；
所述胶结层为环氧橡胶；
所述隔热多层反射层为聚酰亚胺底材，所述聚酰亚胺底材背面镀铝；
将实施例5和对比例1的太阳电池进行辐照试验，结果如下：
试验结果表明，在相同辐照剂量下，高透光薄膜封装后的薄膜太阳电池性能衰减较小。
最后，应当指出，以上实施例仅是本发明较有代表性的例子。显然，本发明的技术方案并不限于上述实施例，还可以有许多变形。本领域的普通技术人员能从本发明公开的内容直接导出或联想到的所有变形，均应认为是本发明的保护范围。
Claims (9)
1.一种体装式一体化柔性太阳电池阵，其特征在于，由上至下依次为高透光薄膜层(5)、胶结层(4)、薄膜太阳电池(3)、胶结层(2)、隔热多层反射层(1)、隔热多层间隔层(6)。
2.如权利要求1所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，包括如下步骤：
1)将薄膜太阳电池串并互连，得串并互连的薄膜太阳电池；
2)将高透光薄膜置于串并互连的薄膜太阳电池的上方，同时将隔热多层反射层置于串并互连的薄膜太阳电池下方；
3)采用热真空封装方法在压力为6×10-3Pa条件下将高透光薄膜、串并互连薄膜太阳电池、隔热多层反射层进行胶结，形成由上至下依次为高透光薄膜层、胶结层、薄膜太阳电池、胶结层、隔热多层反射层的结构，得薄膜太阳电池组件；
4)将薄膜太阳电池组件与隔热多层间隔层进行胶结，即得体装式一体化柔性太阳电池阵。
3.如权利要求2所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，所述的薄膜太阳电池为非晶硅薄膜太阳电池、铜铟镓硒薄膜太阳电池、碲化镉薄膜太阳电池、砷化镓薄膜太阳电池中的任意一种。
4.如权利要求2所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，所述的互连方式为锡焊、电阻焊、导电胶粘结中的任意一种。
5.如权利要求2所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，所述的串联方式为互连片焊接串联或“叠瓦”式串联中的任意一种。
6.如权利要求2所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，所述的高透光薄膜为含氟类聚合物薄膜。
7.如权利要求2所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，所述的高透光薄膜为PTFE、FEP、PVDF、ETFE中的任意一种。
8.如权利要求2所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，所述胶结采用的胶结剂为硅橡胶、EVA、环氧橡胶中的任意一种。
9.如权利要求2所述的体装式一体化柔性太阳电池阵的制备方法，其特征在于，所述隔热多层反射层为聚酰亚胺底材，所述聚酰亚胺底材背面镀金、银或铝中的任意一种。
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