Radiation curable adhesives for reflective laminated solar panels, laminated solar panels including radiation curable adhesives, and/or associated methods
View Patent ↗Certain example embodiments relate to techniques for creating flat laminated mirrors, e.g., for use in concentrating solar power (CSP) applications. In certain example embodiments, the first substrate is a low iron glass substrate. A reflective coating is provided between the first and second substrates. The first and second substrates are laminated together via a radiation curable laminating adhesive with the reflective coating between the substrates. In certain example embodiments the radiation curable laminating adhesive is cured via UV radiation in order to form a laminated reflective article.
1. A method of making an article, the method comprising:
providing a first low-iron glass substrate, the first substrate having a thickness of about 0.5-3 mm;
disposing a reflective coating on a major surface of the first substrate;
disposing a UV radiation curable laminating adhesive over the reflective coating, wherein the laminating adhesive comprises from about 80 to 99.5% total oligomer, from about 1 to 5% adhesion promoter, and from about 0.1 to 1% photoinitiator;
providing a second glass substrate substantially parallel to the first substrate, the second substrate being oriented over the UV radiation curable laminating adhesive;
irradiating the substrates such that UV radiation causes the adhesive to become a solid polymer interlayer to laminate together the first substrate with the reflective coating disposed thereon and the second substrate to form a reflective article, wherein the laminating adhesive is cured using said UV radiation at a wavelength of from about 340 to 430 nm,
wherein the reflective article has a reflectivity of at least 90 percent.
2. The method of claim 1 , wherein the thickness of the first substrate is about 1.6 mm.
3. The method of claim 1 , wherein the laminating adhesive is cured using said UV radiation at a wavelength of from about 350 to 420 nm.
4. The method of claim 1 , wherein the laminating adhesive is cured using said UV radiation at a wavelength of from about 350 to 390 nm.
5. The method of claim 1 , wherein the laminating adhesive is cured using said UV radiation at a wavelength of from about 390 to 420 nm.
6. The method of claim 5 , wherein the second substrate includes more iron than the first substrate.
7. The method of claim 1 , wherein the total oligomer comprises aliphatic urethane acrylate resins.
8. The method of claim 1 , wherein the photoinitiator has maximum UV absorption at from about 350 to 390 nm.
9. The method of claim 1 , wherein the polymer interlayer appears at least one of hazy and sateen following said irradiating.
10. The method of claim 1 , further comprising deleting 0.5-5 mm of the reflective coating from around a periphery of the first substrate.
11. The method of claim 1 , wherein the polymer interlayer has a thickness from about 0.1-1.0 mm after said irradiating.
12. The method of claim 1 , wherein the second substrate is at least twice as thick as the first substrate.
13. The method of claim 1 , wherein the second substrate includes a major surface area that is larger than a major surface area of the first substrate.
14. The method of claim 1 , wherein the reflective coating comprises a plurality of thin film layers including a silver-based layer and a copper-based layer over and contacting the silver-based layer.
15. The method of claim 14 , wherein the reflective coating further comprises a tin-inclusive layer, the tin-inclusive layer being interposed between and contacting both the first substrate and the silver-based layer.
16. The method of claim 15 , wherein the silver-based layer is from about 80 mg per square foot to 95 mg per square foot.
17. The method of claim 1 , wherein the laminating together of the first and second substrates hermetically seals the reflective coating between the first and second substrates.
18. The method of claim 1 , wherein the polymer interlayer appears hazy following said irradiating.
19. The method of claim 1 , wherein the polymer interlayer appears sateen following said irradiating.