CN102066106B - 薄膜光伏组件 - Google Patents
薄膜光伏组件 Download PDFInfo
- Publication number
- CN102066106B CN102066106B CN200980119594.5A CN200980119594A CN102066106B CN 102066106 B CN102066106 B CN 102066106B CN 200980119594 A CN200980119594 A CN 200980119594A CN 102066106 B CN102066106 B CN 102066106B
- Authority
- CN
- China
- Prior art keywords
- polyvinyl butyral
- butyral resin
- resin layer
- substrate
- photovoltaic device
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000010409 thin film Substances 0.000 title abstract description 3
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 claims abstract description 90
- 239000011347 resin Substances 0.000 claims description 114
- 229920005989 resin Polymers 0.000 claims description 113
- 239000000758 substrate Substances 0.000 claims description 44
- 239000004014 plasticizer Substances 0.000 claims description 28
- 238000000034 method Methods 0.000 claims description 25
- 239000000654 additive Substances 0.000 claims description 24
- 230000000996 additive effect Effects 0.000 claims description 23
- 239000004593 Epoxy Substances 0.000 claims description 21
- 238000004519 manufacturing process Methods 0.000 claims description 20
- 239000012528 membrane Substances 0.000 claims description 14
- 238000003475 lamination Methods 0.000 claims description 9
- -1 poly(vinyl butyral) Polymers 0.000 abstract description 12
- 238000007789 sealing Methods 0.000 abstract description 4
- 239000010410 layer Substances 0.000 description 57
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 25
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 22
- OBETXYAYXDNJHR-UHFFFAOYSA-N alpha-ethylcaproic acid Natural products CCCCC(CC)C(O)=O OBETXYAYXDNJHR-UHFFFAOYSA-N 0.000 description 20
- AQPXSEDURNZIDK-UHFFFAOYSA-N 2-ethylbutanoic acid;magnesium Chemical compound [Mg].CCC(CC)C(O)=O AQPXSEDURNZIDK-UHFFFAOYSA-N 0.000 description 18
- 239000010408 film Substances 0.000 description 15
- 239000000203 mixture Substances 0.000 description 13
- 239000000523 sample Substances 0.000 description 13
- 239000004065 semiconductor Substances 0.000 description 13
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 12
- SCVFZCLFOSHCOH-UHFFFAOYSA-M potassium acetate Chemical compound [K+].CC([O-])=O SCVFZCLFOSHCOH-UHFFFAOYSA-M 0.000 description 10
- 239000003513 alkali Substances 0.000 description 9
- 239000003822 epoxy resin Substances 0.000 description 9
- 229920000647 polyepoxide Polymers 0.000 description 9
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 8
- ZTQSAGDEMFDKMZ-UHFFFAOYSA-N Butyraldehyde Chemical compound CCCC=O ZTQSAGDEMFDKMZ-UHFFFAOYSA-N 0.000 description 7
- 238000005516 engineering process Methods 0.000 description 7
- 238000005530 etching Methods 0.000 description 7
- 239000013047 polymeric layer Substances 0.000 description 7
- 238000004448 titration Methods 0.000 description 7
- 239000012496 blank sample Substances 0.000 description 6
- 238000005229 chemical vapour deposition Methods 0.000 description 6
- 238000005240 physical vapour deposition Methods 0.000 description 6
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 5
- 239000004372 Polyvinyl alcohol Substances 0.000 description 5
- VMHLLURERBWHNL-UHFFFAOYSA-M Sodium acetate Chemical compound [Na+].CC([O-])=O VMHLLURERBWHNL-UHFFFAOYSA-M 0.000 description 5
- 238000000151 deposition Methods 0.000 description 5
- GYZLOYUZLJXAJU-UHFFFAOYSA-N diglycidyl ether Chemical compound C1OC1COCC1CO1 GYZLOYUZLJXAJU-UHFFFAOYSA-N 0.000 description 5
- 159000000003 magnesium salts Chemical class 0.000 description 5
- 230000004048 modification Effects 0.000 description 5
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- 229920003023 plastic Polymers 0.000 description 5
- 239000004033 plastic Substances 0.000 description 5
- 229920000642 polymer Polymers 0.000 description 5
- 229920002451 polyvinyl alcohol Polymers 0.000 description 5
- 235000011056 potassium acetate Nutrition 0.000 description 5
- 229910052708 sodium Inorganic materials 0.000 description 5
- 239000011734 sodium Substances 0.000 description 5
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- 235000017281 sodium acetate Nutrition 0.000 description 5
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 4
- KCXVZYZYPLLWCC-UHFFFAOYSA-N EDTA Chemical compound OC(=O)CN(CC(O)=O)CCN(CC(O)=O)CC(O)=O KCXVZYZYPLLWCC-UHFFFAOYSA-N 0.000 description 4
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 229940106691 bisphenol a Drugs 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- WNLRTRBMVRJNCN-UHFFFAOYSA-N hexanedioic acid Natural products OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 229910052700 potassium Inorganic materials 0.000 description 4
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- 239000010703 silicon Substances 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 3
- 239000004411 aluminium Substances 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 125000004432 carbon atom Chemical group C* 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 239000004020 conductor Substances 0.000 description 3
- 150000002148 esters Chemical class 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 230000005855 radiation Effects 0.000 description 3
- 238000002834 transmittance Methods 0.000 description 3
- HGBOYTHUEUWSSQ-UHFFFAOYSA-N valeric aldehyde Natural products CCCCC=O HGBOYTHUEUWSSQ-UHFFFAOYSA-N 0.000 description 3
- 229910004613 CdTe Inorganic materials 0.000 description 2
- 235000000177 Indigofera tinctoria Nutrition 0.000 description 2
- 239000004642 Polyimide Substances 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- KTSFMFGEAAANTF-UHFFFAOYSA-N [Cu].[Se].[Se].[In] Chemical compound [Cu].[Se].[Se].[In] KTSFMFGEAAANTF-UHFFFAOYSA-N 0.000 description 2
- 239000002250 absorbent Substances 0.000 description 2
- 230000002745 absorbent Effects 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 239000001361 adipic acid Substances 0.000 description 2
- 235000011037 adipic acid Nutrition 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- PXKLMJQFEQBVLD-UHFFFAOYSA-N bisphenol F Chemical compound C1=CC(O)=CC=C1CC1=CC=C(O)C=C1 PXKLMJQFEQBVLD-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 150000002118 epoxides Chemical class 0.000 description 2
- 210000003746 feather Anatomy 0.000 description 2
- 244000144992 flock Species 0.000 description 2
- 229920002313 fluoropolymer Polymers 0.000 description 2
- 239000004811 fluoropolymer Substances 0.000 description 2
- 238000005984 hydrogenation reaction Methods 0.000 description 2
- 229940097275 indigo Drugs 0.000 description 2
- COHYTHOBJLSHDF-UHFFFAOYSA-N indigo powder Natural products N1C2=CC=CC=C2C(=O)C1=C1C(=O)C2=CC=CC=C2N1 COHYTHOBJLSHDF-UHFFFAOYSA-N 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 229920005644 polyethylene terephthalate glycol copolymer Polymers 0.000 description 2
- 229920001721 polyimide Polymers 0.000 description 2
- 229920002689 polyvinyl acetate Polymers 0.000 description 2
- 239000011118 polyvinyl acetate Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 229910000077 silane Inorganic materials 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- QKUSYGZVIAWWPY-UHFFFAOYSA-N 1,3-dioxane;7-oxabicyclo[4.1.0]heptane Chemical compound C1COCOC1.C1CCCC2OC21 QKUSYGZVIAWWPY-UHFFFAOYSA-N 0.000 description 1
- DLZBUNUDESZERL-UHFFFAOYSA-N 1-o-heptyl 6-o-nonyl hexanedioate Chemical compound CCCCCCCCCOC(=O)CCCCC(=O)OCCCCCCC DLZBUNUDESZERL-UHFFFAOYSA-N 0.000 description 1
- KUBDPQJOLOUJRM-UHFFFAOYSA-N 2-(chloromethyl)oxirane;4-[2-(4-hydroxyphenyl)propan-2-yl]phenol Chemical compound ClCC1CO1.C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 KUBDPQJOLOUJRM-UHFFFAOYSA-N 0.000 description 1
- OXQGTIUCKGYOAA-UHFFFAOYSA-N 2-Ethylbutanoic acid Natural products CCC(CC)C(O)=O OXQGTIUCKGYOAA-UHFFFAOYSA-N 0.000 description 1
- SSKNCQWPZQCABD-UHFFFAOYSA-N 2-[2-[2-(2-heptanoyloxyethoxy)ethoxy]ethoxy]ethyl heptanoate Chemical compound CCCCCCC(=O)OCCOCCOCCOCCOC(=O)CCCCCC SSKNCQWPZQCABD-UHFFFAOYSA-N 0.000 description 1
- AUZPRCLHJDIEJO-UHFFFAOYSA-N 2-cyclohexylhexanedioic acid Chemical compound OC(=O)CCCC(C(O)=O)C1CCCCC1 AUZPRCLHJDIEJO-UHFFFAOYSA-N 0.000 description 1
- AXDJCCTWPBKUKL-UHFFFAOYSA-N 4-[(4-aminophenyl)-(4-imino-3-methylcyclohexa-2,5-dien-1-ylidene)methyl]aniline;hydron;chloride Chemical compound Cl.C1=CC(=N)C(C)=CC1=C(C=1C=CC(N)=CC=1)C1=CC=C(N)C=C1 AXDJCCTWPBKUKL-UHFFFAOYSA-N 0.000 description 1
- ULPDSNLBZMHGPI-UHFFFAOYSA-N 4-methyl-7-oxabicyclo[4.1.0]heptane Chemical compound C1C(C)CCC2OC21 ULPDSNLBZMHGPI-UHFFFAOYSA-N 0.000 description 1
- MARUHZGHZWCEQU-UHFFFAOYSA-N 5-phenyl-2h-tetrazole Chemical compound C1=CC=CC=C1C1=NNN=N1 MARUHZGHZWCEQU-UHFFFAOYSA-N 0.000 description 1
- GPZYYYGYCRFPBU-UHFFFAOYSA-N 6-Hydroxyflavone Chemical compound C=1C(=O)C2=CC(O)=CC=C2OC=1C1=CC=CC=C1 GPZYYYGYCRFPBU-UHFFFAOYSA-N 0.000 description 1
- BJIUNQZHYLBUNL-UHFFFAOYSA-N 6-heptoxy-6-oxohexanoic acid Chemical compound CCCCCCCOC(=O)CCCCC(O)=O BJIUNQZHYLBUNL-UHFFFAOYSA-N 0.000 description 1
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical class [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- GIMOTOMCGGRGBI-UHFFFAOYSA-M C(CCC)(=O)[O-].C(C)[Mg+] Chemical class C(CCC)(=O)[O-].C(C)[Mg+] GIMOTOMCGGRGBI-UHFFFAOYSA-M 0.000 description 1
- PYGXAGIECVVIOZ-UHFFFAOYSA-N Dibutyl decanedioate Chemical compound CCCCOC(=O)CCCCCCCCC(=O)OCCCC PYGXAGIECVVIOZ-UHFFFAOYSA-N 0.000 description 1
- BRLQWZUYTZBJKN-UHFFFAOYSA-N Epichlorohydrin Chemical compound ClCC1CO1 BRLQWZUYTZBJKN-UHFFFAOYSA-N 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- BDAGIHXWWSANSR-UHFFFAOYSA-N Formic acid Chemical class OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000012963 UV stabilizer Substances 0.000 description 1
- 238000007171 acid catalysis Methods 0.000 description 1
- 239000003377 acid catalyst Substances 0.000 description 1
- 239000011149 active material Substances 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 235000019270 ammonium chloride Nutrition 0.000 description 1
- 239000000908 ammonium hydroxide Substances 0.000 description 1
- 229910021417 amorphous silicon Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- ZFMQKOWCDKKBIF-UHFFFAOYSA-N bis(3,5-difluorophenyl)phosphane Chemical compound FC1=CC(F)=CC(PC=2C=C(F)C=C(F)C=2)=C1 ZFMQKOWCDKKBIF-UHFFFAOYSA-N 0.000 description 1
- XUCHXOAWJMEFLF-UHFFFAOYSA-N bisphenol F diglycidyl ether Chemical compound C1OC1COC(C=C1)=CC=C1CC(C=C1)=CC=C1OCC1CO1 XUCHXOAWJMEFLF-UHFFFAOYSA-N 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 239000007853 buffer solution Substances 0.000 description 1
- PVEOYINWKBTPIZ-UHFFFAOYSA-N but-3-enoic acid Chemical compound OC(=O)CC=C PVEOYINWKBTPIZ-UHFFFAOYSA-N 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000003486 chemical etching Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 229910021419 crystalline silicon Inorganic materials 0.000 description 1
- 125000000113 cyclohexyl group Chemical group [H]C1([H])C([H])([H])C([H])([H])C([H])(*)C([H])([H])C1([H])[H] 0.000 description 1
- MWKFXSUHUHTGQN-UHFFFAOYSA-N decan-1-ol Chemical compound CCCCCCCCCCO MWKFXSUHUHTGQN-UHFFFAOYSA-N 0.000 description 1
- INSRQEMEVAMETL-UHFFFAOYSA-N decane-1,1-diol Chemical compound CCCCCCCCCC(O)O INSRQEMEVAMETL-UHFFFAOYSA-N 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 238000000295 emission spectrum Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- MNWFXJYAOYHMED-UHFFFAOYSA-N heptanoic acid Chemical class CCCCCCC(O)=O MNWFXJYAOYHMED-UHFFFAOYSA-N 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 125000001183 hydrocarbyl group Chemical group 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000002372 labelling Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000004518 low pressure chemical vapour deposition Methods 0.000 description 1
- OJXOOFXUHZAXLO-UHFFFAOYSA-M magnesium;1-bromo-3-methanidylbenzene;bromide Chemical compound [Mg+2].[Br-].[CH2-]C1=CC=CC(Br)=C1 OJXOOFXUHZAXLO-UHFFFAOYSA-M 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000013081 microcrystal Substances 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 238000006386 neutralization reaction Methods 0.000 description 1
- 125000004433 nitrogen atom Chemical group N* 0.000 description 1
- 125000000962 organic group Chemical group 0.000 description 1
- 125000004430 oxygen atom Chemical group O* 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 229920002120 photoresistant polymer Polymers 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920006324 polyoxymethylene Polymers 0.000 description 1
- 235000013824 polyphenols Nutrition 0.000 description 1
- 229920001451 polypropylene glycol Polymers 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- CZMAXQOXGAWNDO-UHFFFAOYSA-N propane-1,1,2-triol Chemical compound CC(O)C(O)O CZMAXQOXGAWNDO-UHFFFAOYSA-N 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Classifications
-
- 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
- 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
- B32B17/1055—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
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
-
- 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
- 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
- B32B17/1055—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
- B32B17/10688—Adjustment of the adherence to the glass layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
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Abstract
本发明提供包括聚乙烯醇缩丁醛层的薄膜光伏器件,该聚乙烯醇缩丁醛层为所述器件提供良好的结合性、电阻率、密封性、可加工性和耐久性。
Description
技术领域
本发明涉及薄膜光伏组件,具体而言,本发明涉及于适当的薄膜光伏衬底之上引入聚合物层和光伏器件的薄膜光伏组件。
背景技术
目前存在两种常用的光伏(太阳能)组件。第一种光伏组件采用半导体晶片作为衬底,第二种光伏组件采用沉积于适当的衬底之上的半导体薄膜。
半导体晶片型光伏组件通常包括常用于各种固态电子器件例如计算机存储器片和计算机处理器的硅晶片。这种常规设计尽管有效但制造费用较高且难以用于非标准应用。
另一方面,薄膜光伏组件可于适当的衬底之上引入一种或多种常规半导体例如非晶硅。与采用复杂精细的制造技术从晶锭上切割晶片的晶片应用不同,薄膜光伏组件采用相对简单的沉积技术例如溅射涂布、物理气相沉积(PVD)或化学气相沉积(CVD)形成。
尽管较晶片型光伏组件而言薄膜光伏组件正成为更可行的实用光伏方案,但现有技术仍需在效率、耐久性和制造费用方面进行改善。
发明内容
本发明提供薄膜光伏器件,该薄膜光伏器件包括为其提供良好结合性、电阻率、密封性、可加工性和耐久性的聚乙烯醇缩丁醛层。
附图说明
图1表示本发明薄膜光伏器件的截面示意图。
具体实施方式
本发明的薄膜光伏器件包括根据本文所述的聚乙烯醇缩丁醛层,该聚乙 烯醇缩丁醛层为所述光伏器件提供良好的结合性、电阻率、密封性、可加工性和耐久性。
本发明薄膜光伏组件的一种实施方案整体标记为10并示于图1中。如图所示,光伏器件14形成于例如可以是玻璃或塑料的基层衬底12之上。保护衬底18经由聚乙烯醇缩丁醛层16与光伏器件14结合。
基层衬底
图1中示作单元12的本发明基层衬底可以是本发明光伏器件能够形成于其上的任何适当的衬底。实例包括但不限于玻璃,形成“硬质”薄膜组件的硬质塑性玻璃料(rigid plastic glazing material),形成“柔性”薄膜组件的塑料薄膜例如聚对苯二甲酸乙二醇酯、聚酰亚胺、含氟聚合物等。通常优选的是基层衬底允许350至1,200纳米范围内的入射辐射大部分透过,但本领域技术人员应当认识到可有多种变型,包括光经由保护衬底进入光伏器件的变型。
薄膜光伏器件
图1中示作单元14的本发明薄膜光伏器件直接形成于基层衬底之上。典型的器件制造根据应用包括:第一导电层的沉积,第一导电层的蚀刻,半导体层的沉积和蚀刻、第二导电层的沉积、第二导电层的蚀刻、总线导体和保护层的施用。可任选地在第一导电层和基层衬底之间于基层衬底之上形成电绝缘层。该任选层例如可以是硅层。
本领域技术人员应当认识到,器件制造的前述说明是一种已知方法并且是本发明的一种实施方案。多种其他类型的薄膜光伏器件落在本发明的范围之内。形成方法和器件的实例包括美国专利文件2003/0180983、7,074,641、6,455,347、6,500,690、2006/0005874、2007/0235073、7,271,333和2002/0034645中所述的实例,在此全部引入其相关制造和器件部分。
薄膜光伏器件的各组成部分可通过任何适当的方法形成。在各种实施方案中,可采用化学气相沉积(CVD)、物理气相沉积(PVD)和/或溅射。
上述两个导电层作为电极输送介于其间的半导体材料所产生的电流。一个电极通常是透明的以允许太阳辐射到达半导体材料。当然,两个导体可均为透明的,或者一个导体为反射的,从而使得穿过半导体材料的光反射回到半导体材料之中。导电层可包含任何适当的导电氧化物材料例如氧化锡或氧化锌,或者如果透明度并不重要(例如对于“背”电极),则可使用金属或金属合 金层例如包含铝或银的层。在其他实施方案中,金属氧化物层可与金属层组合形成电极,所述金属氧化物层可掺有硼或铝并采用低压化学气相沉积进行沉积。导电层的厚度例如可为0.1至10微米。
薄膜光伏器件的光伏区域可包括例如常规PIN或PN结构的氢化非晶硅。硅的厚度通常可达约500纳米,一般包括厚度为3至25纳米的p层、厚度为20至450纳米的i层和厚度为20至40纳米的n层。例如,如美国专利4,064,521所述,沉积可借助在硅烷或硅烷和氢的混合物中进行辉光放电。
或者,半导体材料可以是微晶硅,碲化镉(CdTe或CdS/CdTe),二硒化铜铟(CuInSe2、“CIS”、或CdS/CuInSe2),硒化铜铟镓(CuInGaSe2或“CIGS”),或其他光伏活性材料。本发明的光伏器件可具有附加的半导体层或前述半导体类型的组合,并可为串列、三结点或异质结结构。
可采用任意常规的半导体制造技术,包括但不限于使用抗蚀掩模的丝网印刷、使用正性或负性光致抗蚀剂的蚀刻、机械划刻、放电划刻、化学蚀刻或激光蚀刻,进行各层的蚀刻,以形成器件的各组成部分。各层的蚀刻通常致使在器件中形成独立的光电池。可使用在制造过程的任意合适阶段插入或形成的母线,将这些光电池相互电连接。
在与聚乙烯醇缩丁醛层和保护衬底组合之前,可任选地在所述光电池之上形成保护层。保护层例如可以是经溅射的铝。
由任选的绝缘层、导电层、半导体层和任选的保护层形成的相互电连接的光电池形成本发明的光伏器件。
聚乙烯醇缩丁醛层
本发明的薄膜光伏组件使用任选地包含环氧树脂的聚乙烯醇缩丁醛层作为层压结合体,该层压结合体用于将光伏器件密封于保护衬底,从而形成本发明的光伏组件。
薄膜光伏器件固有地难以层压,这是因为层压体内存在母线。这些母线为力聚集体,在层压过程中造成过早密封,从而明显降低排气质量。此外,母线通常在层压步骤中聚乙烯醇缩丁醛必须流入的厚度上呈现阶梯式变化。
本发明的聚乙烯醇缩丁醛层可包含如表所示平均分子量为70,000至150,000道尔顿或80,000至120,000道尔顿的聚乙烯醇缩丁醛树脂。
本发明的薄膜光伏聚乙烯醇缩丁醛层的其他组成部分的数值也可在表中 查到:
本发明的聚乙烯醇缩丁醛层包括小分子量的环氧添加剂。如本领域所知(例如参见美国专利5,529,848和5,529,849),任何适当的环氧添加剂可用于本发明。
在各实施方案中,如下所述可使用的环氧成分选自:(a)主要包括双酚A的单体二环氧甘油醚的环氧树脂;(b)主要包括双酚F的单体二环氧甘油醚的环氧树脂;(c)主要包括双酚A的氢化二环氧甘油醚的环氧树脂;(d)聚环氧酚醛树脂;(e)聚乙二醇的二环氧化物,或称作环氧端基聚醚;和(f)任意前述环氧树脂(a)至(e)的混合物(参见Encyclopedia of Polymer Science and Technology,卷6,1967,Interscience Publishers,N.Y.,209-271页)。
适宜的可商购的(a)类双酚A二环氧甘油醚为得自Dow ChemicalCompany的DER 331。(b)类双酚F二环氧甘油醚环氧树脂为EPON ResinDPL-862,(c)类双酚A氢化二环氧甘油醚树脂为EPONEX Resin 1510,二者均可得自Shell Chemical Company。(d)类聚环氧酚甲醛可得自Dow Chemical如DEN 431。
在优选实施方案中,使用(e)类聚氧丙二醇的二环氧化物并可得自Dow Chemical如DER 732。
适宜的环氧添加剂的其他实例包括美国专利3,723,320中所述类型的3,4-环氧环己烷甲酸酯成分。还可使用二环氧化物,例如美国专利4,206,067中所披露的那些,所述二环氧化物包含两个各自与环氧基结合的连接的环己基。所述二环氧化物相应于通式I:
通式I:
其中R3为包含1至10个碳原子、0至6个氧原子和0至6个氮原子的有机基团,R4至R9独立地选自氢和包含1至5个碳原子的脂族基团。示例性二环氧化物包括3,4-环氧环己基甲基-3,4-环氧环己烷、二(3,4-环氧-6-甲基环己基甲基己二酸酯)和2-(3,4-环氧环己基)-5,5-螺(3,4-环氧)环己烷-m-二氧杂环己烷。
其他可使用的环氧树脂为2-乙基己基甘油醚(可得自Resolution Products,Houston Texas如Heloxy Modifier 116)。
其他可使用的环氧化物包括聚氧丙二醇的二环氧化物、2-乙基己基甘油醚、表氯醇和聚丙二醇的二环氧化产物。
还可使用环氧添加剂的混合物。
可将任意适量的环氧添加剂引入聚乙烯醇缩丁醛层。在各实施方案中,环氧添加剂的引入如表所示。这些量可应用于以上所列的任意环氧添加剂,特别是通式I所示的那些,以及本文所述环氧添加剂混合物的总量。
除了所用聚乙烯醇缩丁醛树脂和所用环氧添加剂的分子量的选择之外,另一参数是聚合物层的体电阻率,因为该参数对光伏组件的漏电流和效率具有直接影响。
常规聚乙烯醇缩丁醛中间层在标准湿度下具有约1012Ω-cm的体电阻率。然而,在聚合物层会暴露于环境的组件边缘处,根据环境状况体电阻率可降至1011Ω-cm或以下。
本发明的聚合物层优选保持至少5×1011Ω-cm的体电阻率。
本发明的结合性控制剂(ACA)包括美国专利5,728,472披露的那些。另外,可通过改变酸中和时相关氢氧化物的用量,调节剩余的醋酸钠和/或醋酸钾。在各实施方案中,本发明的聚合物层除包括醋酸钠和/或醋酸钾以外还包括二(2-乙基)丁酸镁(化学文摘登记号79992-76-0)。如表所示,可按照有效控制聚合物层结合性的含量包含所述镁盐。
如本文所用,可采用以下方法确定片状样品中醋酸钠和醋酸钾的“滴度”(如本文所用“总的碱滴度”)和镁盐的“滴度”:
为了确定所称重的各片状样品中树脂的含量,采用以下公式,其中X定义为包含增塑剂及任何其他添加剂的树脂相对于初始片状样品制品中的树脂的每百磅的磅数。
以大约5g片状样片中的树脂为目标质量,估算开始的片状样品的量,并在各滴度测定中使用计算的片状样品中的树脂量。所有滴定应于同一日内完成。
将片状样品溶于烧杯内250ml甲醇中。片状样品完全溶解可能花费8小时。此外在烧杯内准备仅有甲醇的空白样。使用程控在pH为2.5时停止的自动pH滴定仪,各自以0.00500标准HCl滴定样品和空白样。记录pH达到4.2时各自添加到样品和空白样中的HCl量。根据下式确定HCl的滴度:
采用以下步骤确定镁盐的滴度:
将12至15ml pH 10.00缓冲液(通过使用甲醇将54克氯化铵和350ml氢氧化铵稀释至1升制得)和12至15ml Erichrome Black T指示剂添加到如上所述均已使用HCl滴定的空白样和各片状样品中。然后将滴定剂变为0.000298g/ml EDTA溶液,该溶液通过使用甲醇将0.3263g二水合乙二胺四乙酸四钠和5ml水稀释至1升制得。通过596nm下的透光度测量EDTA滴定。在开始滴定之前首先将样品或空白样中的%透光度调整为100%,此时溶液为亮品红色。当596nm下的透光度不变时,EDTA滴定完成,溶液将为暗靛蓝色。 记录空白样和各片状样品达到靛蓝终点所滴定的EDTA体积。根据下式确定镁盐滴度:
可根据该结果按照下式计算碱的总滴度(1×10-7mol醋酸盐/g树脂):
碱的总滴度=片的HCl滴度-(2×镁盐的总滴度)
如上所述,可通过首先确定碱的总滴度,来确定碱的总滴度中归属于醋酸钠或醋酸钾的部分。在确定碱的总滴度之后,可通过感应耦合等离子发射谱(ICP)对聚合物片进行破坏性分析,从而得到钾的ppm浓度和钠的ppm浓度。
本文将归属于醋酸钠的碱滴度定义为碱的总滴度乘以[ppm钠/(ppm钠+ppm钾)]。
本文将归属于醋酸钾的碱滴度定义为碱的总滴度乘以[ppm钾/(ppm钠+ppm钾)]。
可通过已知的缩醛化方法制备聚乙烯醇缩丁醛,所述方法包括在酸催化剂存在的条件下使聚乙烯醇与丁醛反应,随后进行催化剂的中和,树脂的分离、稳定和干燥。
如本文所用,“树脂”是指从酸催化和随后聚合前体中和产生的混合物中取出的聚乙烯醇缩丁醛组分。除聚乙烯醇缩丁醛以外树脂通常还含有其他组分,例如醋酸根、盐和醇。
聚乙烯醇缩丁醛树脂的适宜制备方法的细节是本领域技术人员已知的(例如参见美国专利2,282,057和2,282,026)。在一种实施方案中,可采用B.E.Wade在Encyclopedia of Polymer Science&Technology,第三版,卷8,第381-399页(2003)中的Vinyl Acetal Polymers所述的溶剂法。在另一实施方案中,可采用其中所述的水合法。可从例如Solutia Inc.,St.Louis,Missouri商购各种形式的聚乙烯醇缩丁醛如ButvarTM树脂。
如本文所用,术语“分子量”是指重均分子量。除了表中提供的范围之外,本发明的聚乙烯醇缩丁醛层还可具有120,000-150,000道尔顿、100,000-120,000道尔顿、70,000-120,000道尔顿或70,000-120,000道尔顿的分子量。
可将任意适当的增塑剂添加到本发明的聚乙烯醇缩丁醛树脂中以形成聚 乙烯醇缩丁醛层。本发明的聚乙烯醇缩丁醛层中所使用的增塑剂可包括多元酸或多元醇的酯等。适当的增塑剂例如包括:三乙二醇二-(2-乙基丁酸酯),三乙二醇二-(2-乙基己酸酯),三乙二醇二庚酸酯,四乙二醇二庚酸酯,己二酸二己酯,己二酸二辛酯,环己基己二酸己酯,己二酸庚酯和己二酸壬酯的混合物,己二酸二异壬酯,己二酸庚基壬基酯,癸二酸二丁酯,聚合物增塑剂例如油改性的癸二醇酸,磷酸酯与诸如美国专利3,841,890中披露的己二酸酯和诸如美国专利4,144,217中披露的己二酸酯的混合物,以及前述之混合物和组合物。所能使用的其他增塑剂为C4至C9烷基醇和环C4至C10醇(如美国专利5,013,779披露)以及C6至C8己二酸酯(如己二酸己酯)制成的混合己二酸酯。在优选实施方案中,增塑剂为三乙二醇二-(2-乙基己酸酯)。除了表中给出的增塑剂含量以外,增塑剂的含量还可以为25-35phr、15-25phr、5-15phr或0-5phr。
在一些实施方案中,增塑剂具有少于20个、少于15个、少于12个或少于10个碳原子的烃片段。
可将添加剂引入聚乙烯醇缩丁醛层以提高其在最终产品中的性能。所述添加剂如本领域所知包括但不限于增塑剂、染料、颜料、稳定剂(如紫外稳定剂)、抗氧化剂、阻燃剂、其他IR吸收剂、UV吸收剂、抗阻剂、前述添加剂的组合等。
形成聚乙烯醇缩丁醛层的一种示例性方法包括:挤出包含树脂、增塑剂和添加剂的熔融聚乙烯醇缩丁醛,然后将熔体推入片状模具(例如开口在一个尺度上明显大于垂直尺度的模具)。形成聚乙烯醇缩丁醛的另一示例性方法包括:将模具中的熔体投于轧辊之上,使熔体固化,随后取出片状固化熔体。
如本文所用,“熔体”是指树脂与增塑剂以及任选的其他添加剂的混合物。在任一实施方案中,可通过调整模具开口表面或在轧辊表面提供纹理,控制层任意一面或两面之上的表面纹理。控制层的纹理的其他方法包括改变材料参数(例如树脂和/或增塑剂的水含量、熔体温度、聚乙烯醇缩丁醛的分子量分布或前述参数的组合)。此外,所述层可构造为包括限定暂时性表面不平整度的间隔突起,以有助于层压工艺过程中层的排气,在层压工艺之后层压工艺的高温高压使所述突起熔于层中,从而形成光滑表面。
如本文所用,残余羟基含量(乙烯基羟基含量或聚乙烯醇(PVOH)含量的形式)是指工艺完成之后作为侧基保留在聚合物链上的羟基的含量。例如,可通过使聚醋酸乙烯水解为聚乙烯醇并随后使聚乙烯醇与丁醛反应来形成聚乙烯醇缩丁醛。在聚醋酸乙烯水解的过程中,通常并不是所有醋酸侧基均转变为羟基。此外,与丁醛反应通常不会使所有羟基转变为醛基。因而,在任何制成的聚乙烯醇缩丁醛中,通常在聚合物链上会存在作为侧基的残余醋酸根(乙烯基醋酸根形式)和残余羟基(乙烯基羟基形式)。如本文所用,根据ASTM1396基于重量百分比测量残余羟基含量。除了表中提供的数值以外,本发明的聚乙烯醇缩丁醛可具有10-15或15-17重量百分比的残余羟基含量。
在本发明的各实施方案中,使用下述具体的成分组合:
110,000-130,000道尔顿聚乙烯醇缩丁醛、8-12phr三乙二醇二-(2-乙基己酸酯)、17-21%残余羟基、8-12滴度二(2-乙基丁酸)镁,4.2×1015+/-10%体电阻率。
40,000-60,000道尔顿聚乙烯醇缩丁醛、8-12phr三乙二醇二-(2-乙基己酸酯)、17-21%残余羟基、8-12滴度二(2-乙基丁酸)镁、2.8×1015+/-10%体电阻率。
110,000-130,000道尔顿聚乙烯醇缩丁醛、18-22phr三乙二醇二-(2-乙基己酸酯)、17-21%残余羟基、8-12滴度二(2-乙基丁酸)镁、2.6×1014+/-10%体电阻率。
140,000-150,000道尔顿聚乙烯醇缩丁醛、32-40phr三乙二醇二-(2-乙基己酸酯)、17-21%残余羟基、8-12滴度二(2-乙基丁酸)镁、1.8-2.2phr环氧树脂DERTM-732、1×1012+/-10%体电阻率。
110,000-130,000道尔顿聚乙烯醇缩丁醛、30-38phr三乙二醇二-(2-乙基己酸酯)、18.7%残余羟基、8-12滴度二(2-乙基丁酸)镁、8.0×1012+/-10%体电阻率。
140,000-150,000道尔顿聚乙烯醇缩丁醛、27-35phr三乙二醇二-(2-乙基己酸酯)、14-18%残余羟基、8-12滴度二(2-乙基丁酸)镁、3.5×1013+/-10%体电阻率。
210,000-230,000道尔顿聚乙烯醇缩丁醛、20-28phr三乙二醇二-(2-乙基己酸酯)、9-13%残余羟基、8-12滴度二(2-乙基丁酸)镁、2.7×1014+/-10%体电阻率。
40,000-60,000道尔顿聚乙烯醇缩丁醛、16-24phr三乙二醇二-(2-乙基己酸酯)、17-21%残余羟基、8-12滴度二(2-乙基丁酸)镁、2.8×1015+/-10%体电阻率。
40,000-60,000道尔顿聚乙烯醇缩丁醛、21-29phr三乙二醇二-(2-乙基己酸酯)、17-21%残余羟基、8-12滴度二(2-乙基丁酸)镁、1.5×1014+/-10%体电阻率。
保护衬底
图1中示作单元18的本发明保护衬底可以是本发明的光伏器件能够形成于其上的任意适当的衬底。实例包括但不限于玻璃,硬质塑料和塑料薄膜(如聚对苯二甲酸乙二醇酯、聚酰亚胺、含氟聚合物)等。通常优选的是保护衬底允许350至1,200纳米范围内的入射辐射大部分透过,但本领域技术人员应当认识到可有多种变型,包括进入光伏器件的所有光经由基层衬底进入的变型。在这些实施方案中,保护衬底无需为透明的,或大多无需为透明的,并可为例如防止光通过保护衬底离开光伏组件的反射膜。
组装
本发明薄膜光伏组件的最终组装包括:使用已形成于基层衬底之上的母线(如果适用)配置与薄膜光伏器件接触的聚乙烯醇缩丁醛层,配置与聚乙烯醇缩丁醛接触的保护衬底,层压形成组件。
本发明包括光伏组件的制造方法,该方法包括以下步骤:提供基层衬底、于所述基层衬底之上形成光伏器件、使用本发明的聚乙烯醇缩丁醛层将光伏器件层压于保护衬底。
本发明包括光伏组件,该光伏组件包括本发明的聚合物层。
实施例
实施例1:
采用分子量为110,000-130,000道尔顿的聚乙烯醇缩丁醛树脂、10份/100份树脂(phr)三乙二醇二-(2-乙基己酸酯)增塑剂、18.7%的残余羟基含量和10滴度二(2-乙基丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有4.2×1015的体电阻率和31微米的DF-135。如本文所用,“DF135”是与高压釜流量(autoclave flow)和中间层成功层压具有母线的复杂组件的能力相关的试验。DF135是将中间层温度升至135℃时特定探针以规定的恒定作用力深入中间 层的深度的量度。
实施例2:
采用分子量为40,000-60,000道尔顿的聚乙烯醇缩丁醛树脂、10phr三乙二醇二-(2-乙基己酸酯)增塑剂、19.0%的残余羟基含量和10滴度二(2-乙基丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有2.8×1015的体电阻率和407微米的DF135。
实施例3:
采用分子量为110,000-130,000道尔顿的聚乙烯醇缩丁醛树脂、20phr三乙二醇二-(2-乙基己酸酯)增塑剂、18.7%的残余羟基含量和10滴度二(2-乙基丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有2.6×1014的体电阻率和80微米的DF135。
实施例4:
采用分子量为140,000-150,000道尔顿的聚乙烯醇缩丁醛树脂、36phr三乙二醇二-(2-乙基己酸酯)增塑剂、18.7%的残余羟基含量、10滴度二(2-乙基丁酸)镁和2phr环氧树脂DERTM-732,制造聚乙烯醇缩丁醛中间层。制成的片具有1×1012的体电阻率和136微米的DF135。
实施例5:
采用分子量为110,000-130,000道尔顿的聚乙烯醇缩丁醛树脂、34phr三乙二醇二-(2-乙基己酸酯)增塑剂、18.7%的残余羟基含量和10滴度二(2-乙基丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有8.0×1012的体电阻率和220微米的DF135。
实施例6:
采用分子量为140,000-150,000道尔顿的聚乙烯醇缩丁醛树脂、31phr三乙二醇二-(2-乙基己酸酯)增塑剂、16.3%的残余羟基含量和10滴度二(2-乙基丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有3.5×1013的体电阻率和277微米的DF135。在25%和85%的相对湿度下片的平衡湿度分别为0.33%和1.89%。
实施例7:
采用分子量为210,000-230,000道尔顿的聚乙烯醇缩丁醛树脂、24phr三乙二醇二-(2-乙基己酸酯)增塑剂、10.7%的残余羟基含量和10滴度二(2-乙基 丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有2.7×1014的体电阻率和47微米的DF135。在25%和85%的相对湿度下片的平衡湿度分别为0.22%和1.40%。
实施例8:
采用分子量为40,000-60,000道尔顿的聚乙烯醇缩丁醛树脂、20phr三乙二醇二-(2-乙基己酸酯)增塑剂、19%的残余羟基含量和10滴度二(2-乙基丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有2.8×1015的体电阻率和564微米的DF135。
实施例9:
采用分子量为40,000-60,000道尔顿的聚乙烯醇缩丁醛树脂、25phr三乙二醇二-(2-乙基己酸酯)增塑剂、19.0%的残余羟基含量和10滴度二(2-乙基丁酸)镁,制造聚乙烯醇缩丁醛中间层。制成的片具有1.5×1014的体电阻率和564微米的DF135。
根据本发明,目前可提供具有良好物理稳定性的薄膜光伏组件。
尽管结合示例性实施方案对本发明进行了描述,但本领域技术人员应当理解在不脱离本发明范围的情况下可作出各种改变并可以等同物代替本发明的要素。另外,在不脱离本发明真正构思的情况下可作出多种改进,以使特定的情形或物质适于本发明的教导。因而,本发明不限于预期作为实施本发明的最佳方案所披露的具体实施方案,而是包括落在所附权利要求范围内的所有实施方案。
此外,应当理解的是,在适宜的情况下,针对本发明的任意一种组分给出的任意范围、数值或特性可与针对本发明的任意其他组分给出的任意范围、数值或特性互换使用,以形成如本文给出的各组分具有限定数值的实施方案。例如,可组合聚乙烯醇缩丁醛环氧化物的范围和增塑剂的范围,以形成落在本发明范围内但罗列过于繁冗的多种变换方案。
摘要或任意权利要求中给出的任意附图标记仅出于示例性目的,不应解释为将本发明限定于任意附图所示的任一具体实施方案。
附图未按照比例绘制,除非另外说明。
在此引入本发明提及的各参考文献(包括期刊文献、专利、专利申请和书籍)的全部内容作为参考。
Claims (16)
1.一种薄膜光伏组件,包括:
基层衬底;
设置为与所述基层衬底接触的薄膜光伏器件;
设置为与所述光伏器件接触的聚乙烯醇缩丁醛层;和
设置为与所述聚乙烯醇缩丁醛层接触的保护衬底,
其中所述聚乙烯醇缩丁醛层包含5-15份/百份树脂的增塑剂并具有70,000-120,000道尔顿的分子量。
2.权利要求1的组件,其中所述聚乙烯醇缩丁醛层具有100,000-120,000道尔顿的分子量。
3.一种薄膜光伏组件,包括:
基层衬底;
设置为与所述基层衬底接触的薄膜光伏器件;
设置为与所述光伏器件接触的聚乙烯醇缩丁醛层;和
设置为与所述聚乙烯醇缩丁醛层接触的保护衬底,
其中所述聚乙烯醇缩丁醛层包含0-5份/百份树脂的增塑剂并具有70,000-100,000道尔顿的分子量。
4.权利要求1的组件,其中所述聚乙烯醇缩丁醛层还包含0-5份/百份树脂的环氧添加剂。
5.权利要求1的组件,其中所述聚乙烯醇缩丁醛层还包含0-2份/百份树脂的环氧添加剂。
6.权利要求3的组件,其中所述聚乙烯醇缩丁醛层还包含0-5份/百份树脂的环氧添加剂。
7.权利要求3的组件,其中所述聚乙烯醇缩丁醛层还包含0-2份/百份树脂的环氧添加剂。
8.权利要求1的组件,其中所述聚乙烯醇缩丁醛具有4.2×1015+/-10%的体电阻率。
9.一种制造薄膜光伏组件的方法,包括:
提供基层衬底;
在所述基层衬底之上形成薄膜光伏器件;
设置与所述薄膜光伏器件接触的聚乙烯醇缩丁醛层;
设置与所述聚乙烯醇缩丁醛层接触的保护衬底;和
层压所述基层衬底、所述光伏器件、所述聚乙烯醇缩丁醛层及所述保护衬底以形成所述组件,其中所述聚乙烯醇缩丁醛层包含5-15份/百份树脂的增塑剂并具有70,000-120,000道尔顿的分子量。
10.权利要求9的方法,其中所述聚乙烯醇缩丁醛层具有100,000-120,000道尔顿的分子量。
11.一种制造薄膜光伏组件的方法,包括:
提供基层衬底;
在所述基层衬底之上形成薄膜光伏器件;
设置与所述薄膜光伏器件接触的聚乙烯醇缩丁醛层;
设置与所述聚乙烯醇缩丁醛层接触的保护衬底;和
层压所述基层衬底、所述光伏器件、所述聚乙烯醇缩丁醛层及所述保护衬底以形成所述组件,其中所述聚乙烯醇缩丁醛层包含0-5份/百份树脂的增塑剂并具有70,000-100,000道尔顿的分子量。
12.权利要求9的方法,其中所述聚乙烯醇缩丁醛层还包含0-5份/百份树脂的环氧添加剂。
13.权利要求9的方法,其中所述聚乙烯醇缩丁醛层还包含0-2份/百份树脂的环氧添加剂。
14.权利要求11的方法,其中所述聚乙烯醇缩丁醛层还包含0-5份/百份树脂的环氧添加剂。
15.权利要求11的方法,其中所述聚乙烯醇缩丁醛层还包含0-2份/百份树脂的环氧添加剂。
16.权利要求9的方法,其中所述聚乙烯醇缩丁醛具有4.2×1015+/-10%的体电阻率。
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Application Number | Priority Date | Filing Date | Title |
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US5626008P | 2008-05-27 | 2008-05-27 | |
US61/056,260 | 2008-05-27 | ||
US12/472,444 US20090293952A1 (en) | 2008-05-27 | 2009-05-27 | Thin Film Photovoltaic Module |
US12/472,444 | 2009-05-27 | ||
PCT/US2009/045226 WO2009151952A2 (en) | 2008-05-27 | 2009-05-27 | Thin film photovoltaic module |
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CN102066106A CN102066106A (zh) | 2011-05-18 |
CN102066106B true CN102066106B (zh) | 2014-10-08 |
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US (1) | US20090293952A1 (zh) |
EP (1) | EP2285566A2 (zh) |
JP (1) | JP2011522419A (zh) |
KR (1) | KR20110026428A (zh) |
CN (1) | CN102066106B (zh) |
BR (1) | BRPI0912135A2 (zh) |
WO (1) | WO2009151952A2 (zh) |
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CN102656701B (zh) * | 2009-12-15 | 2016-05-04 | 第一太阳能有限公司 | 光伏窗口层 |
KR102088404B1 (ko) | 2010-08-23 | 2020-03-12 | 주식회사 쿠라레 | 태양 전지용 봉지재 및 합판 유리용 중간막 |
KR101491707B1 (ko) | 2011-06-28 | 2015-02-09 | 가부시키가이샤 구라레 | 태양 전지용 밀봉재 및 접합유리용 중간막 |
US20130074931A1 (en) | 2011-09-22 | 2013-03-28 | Wenjie Chen | Polymer interlayers comprising epoxidized vegetable oil |
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CN103171121B (zh) * | 2011-12-26 | 2016-01-20 | 上海晶棠安全玻璃技术应用研究中心 | 一种太阳能光伏发电用pvb夹胶膜制造方法 |
US9833976B2 (en) * | 2012-03-09 | 2017-12-05 | Solutia Inc. | Defect resisting acoustic polymer interlayers |
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US9573329B2 (en) | 2014-12-08 | 2017-02-21 | Solutia Inc. | Poly(vinyl acetal) resin compositions, layers, and interlayers having enhanced optical properties |
US9925746B2 (en) | 2014-12-08 | 2018-03-27 | Solutia Inc. | Poly(vinyl acetal) resin compositions, layers, and interlayers having enhanced optical properties |
US9809006B2 (en) | 2014-12-08 | 2017-11-07 | Solutia Inc. | Polymer interlayers having improved sound insulation properties |
EP3196012A1 (en) | 2016-01-20 | 2017-07-26 | AGC Glass Europe | Organic photovoltaic assembly and process of manufacture |
EP3196013A1 (en) | 2016-01-20 | 2017-07-26 | AGC Glass Europe | Organic photovoltaic assembly and process of manufacture |
CN109153606A (zh) * | 2016-10-12 | 2019-01-04 | 积水化学工业株式会社 | 夹层玻璃用中间膜、卷体以及夹层玻璃 |
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- 2009-05-27 BR BRPI0912135A patent/BRPI0912135A2/pt not_active Application Discontinuation
- 2009-05-27 US US12/472,444 patent/US20090293952A1/en not_active Abandoned
- 2009-05-27 CN CN200980119594.5A patent/CN102066106B/zh not_active Expired - Fee Related
- 2009-05-27 JP JP2011511767A patent/JP2011522419A/ja active Pending
- 2009-05-27 EP EP09763243A patent/EP2285566A2/en not_active Withdrawn
- 2009-05-27 KR KR1020107028643A patent/KR20110026428A/ko not_active Application Discontinuation
- 2009-05-27 WO PCT/US2009/045226 patent/WO2009151952A2/en active Application Filing
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Also Published As
Publication number | Publication date |
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CN102066106A (zh) | 2011-05-18 |
WO2009151952A2 (en) | 2009-12-17 |
KR20110026428A (ko) | 2011-03-15 |
US20090293952A1 (en) | 2009-12-03 |
JP2011522419A (ja) | 2011-07-28 |
BRPI0912135A2 (pt) | 2015-11-03 |
WO2009151952A3 (en) | 2010-10-07 |
EP2285566A2 (en) | 2011-02-23 |
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