CN102166868A - 用于太阳能模块的背层 - Google Patents
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Abstract
本发明公开了一种用于太阳能模块的背层。此背层包括第一聚合层、第二聚合层及水气阻层。第一聚合层包括线性低密度聚乙烯(LLDPE)、低密度聚乙烯(LDPE)、中密度聚乙烯(MDPE)、高密度聚乙烯(HDPE)或聚碳酸酯(PC)。第二聚合层包括线性低密度聚乙烯(LLDPE)、低密度聚乙烯(LDPE)、中密度聚乙烯(MDPE)、高密度聚乙烯(HDPE)、聚碳酸酯(PC)或耐纶。水气阻层配置在第一聚合层与第二聚合层之间。
Description
技术领域
本发明是有关于一种封装层,且特别是有关于一种用于太阳能模块的背层。
背景技术
因太阳能似乎是用之不尽的能源,所以引起许多研究注意。因此,人们开发太阳能模块以将太阳能直接转换为电能。
通常,太阳能模块机械性地支撑其中的太阳能电池,且保护太阳能电池免于受环境影响而劣化。太阳能模块通常包含刚性且透明的一个保护前板(例如玻璃)以及一个后板或背层(其一般称为背层)。前板及背层将太阳能电池封装起来,并因此保护太阳能电池免受环境影响而退化。
然而,太阳能工业的目标是开发使用寿命长达数十年(例如,20年)的太阳能模块。因此,背层必须具有能够抵抗应力冲击及热冲击的耐损害能力,以及将湿度、温度及紫外线辐射所导致的劣化程度最小化。背层的进一步考虑在于其成本必须是商业上可接受的。
在先前技术中,曾揭示一种包含聚氟乙烯或其它氟化聚合物(诸如,聚乙烯-四氟乙烯或聚乙烯-氯三氟乙烯)的背层。然而,氟化聚合物通常是昂贵的。除氟化聚合物之外,用在背层中的其它聚合物的价格也是相对高昂的。举例而言,聚对苯二甲酸乙二酯亦能成为背层结构的一部分材料,此类聚对苯二甲酸乙二酯必须经过昂贵的定向制程来形成定向膜。此外,另一种用于可挠性光伏打模块的背层结构的聚酰亚胺也是昂贵的聚合物。因此,目前仍亟需一种成本更低的背层。
发明内容
本发明的目的在于提供一种用于太阳能模块的背层。
此背层包括第一聚合层、第二聚合层及水气阻层。第一聚合层包括选自由以下组成的群组中的至少一种聚合物:线性低密度聚乙烯(LLDPE)、低密度聚乙烯(LDPE)、中密度聚乙烯(MDPE)、高密度聚乙烯(HDPE)及聚碳酸酯(PC)。第二聚合层具有大于90℃的熔点,且包括选自由以下组成的群组的至少一种聚合物:线性低密度聚乙烯(LLDPE)、低密度聚乙烯(LDPE)、中密度聚乙烯(MDPE)、高密度聚乙烯(HDPE)、聚碳酸酯(PC)及耐纶。水气阻层配置在该第一聚合层与该第二聚合层之间。
根据本发明一实施方式,第一聚合层具有一相同于第二聚合层的组成。
根据本发明一实施方式,第一聚合层还包含至少一改质剂是选自由稳定剂、颜料、填充剂及偶合剂所组成的群组。
根据本发明一实施方式,上述偶合剂包含硅烷。
根据本发明一实施方式,第一聚合层还包含一接枝剂,且接枝剂包含至少一丙烯酸以及顺丁烯二酸酐。
根据本发明一实施方式,第一聚合层还包含一含有有机过氧化物的一化学交联剂。
根据本发明一实施方式,上述有机过氧化物是选自由过氧化二异丙苯、1-双(叔丁基过氧基)-3,3,5-三甲基环己烷以及a,a′-二(叔丁基过氧基)二异丙苯所组成的群组。
根据本发明一实施方式,第一聚合层由一聚合体掺合物(polymer blend)制成。
根据本发明一实施方式,水气阻层包含一聚合物是选自由乙烯-乙烯醇共聚物以及聚偏二氯乙烯(PVDC)所组成的群组。
根据本发明一实施方式,水气阻层由铝或不锈钢制成。
本文所揭示的背层是由价格低廉的聚合物所制成,且具有好的耐候性,可兼顾实用性与制造成本。在一实施例中,可借由对第一聚合层施加热量,而将背层的第一聚合层直接黏着至一太阳能电池,因为本发明所揭露的第一聚合层为诸如PE或PC的热塑性聚合物。因此,不再需要额外的黏着剂,并因此可降低组装太阳能电池及背层所花费的操作成本。
附图说明
为让本发明的上述和其它目的、特征、优点与实施例能更明显易懂,所附附图的说明如下:
图1为图示根据本发明的一实施例的背层的横截面图。
【主要附图标记说明】
100背层
110第一聚合层
120第二聚合层
130水气阻层
140第一黏着层
150第二黏着层
具体实施方式
为了使本揭示内容的叙述更加详尽与完备,下文针对了本发明的实施方式与具体实施例提出了说明性的描述;但这并非实施或运用本发明具体实施例的唯一形式。以下所揭露的各实施例,在有益的情形下可相互组合或取代,也可在一实施例中附加其它的实施例,而无须进一步的记载或说明。
在以下描述中,将详细叙述许多特定细节以使读者能够充分理解以下的实施例。然而,可在无此等特定细节的情况下实践本发明的实施例。在其它情况下,为简化附图,熟知的结构与装置仅示意性地绘示于图中。
下文揭示一种用于太阳能模块的背层。图1为本发明一实施例的背层100的横截面图。如图1所示,背层100包括第一聚合层110、第二聚合层120及水气阻层130。
第一聚合层110用以黏贴至太阳能电池。第一聚合层110的合适的材料包括但不限于线性低密度聚乙烯(LLDPE)、低密度聚乙烯(LDPE)、中密度聚乙烯(MDPE)、高密度聚乙烯(HDPE)以及聚碳酸酯(PC)。在本发明中,低密度聚乙烯指密度在0.910g/cm3至0.940g/cm3范围的聚乙烯。中密度聚乙烯指密度在0.926g/cm3至0.940g/cm3范围的聚乙烯。高密度聚乙烯指指密度大于或等于0.941g/cm3的聚乙烯。在一些实施例中,第一聚合层110可由含有上述至少一聚合物的聚合体掺合物(polymer blend)所制成。举例而言,聚合体掺合物可为HDPE与其它等级的HDPE树脂、MDPE、LDPE或LLDPE组成的聚合体掺合物。另外,本文所揭示的第一聚合层是由价格低廉的聚合物所制成,诸如PE或PC,因此可降低背层的制造成本。
在一实施方式中,第一聚合层110的厚度为约0.05mm至约2mm,且第一聚合层110的熔点高于90℃,上述熔点是借由示差扫描热量分析仪(differential scanning calorimetry)来量测。在一实施例中,第一聚合层110可由熔点约110℃至约130℃的HDPE制成。在其它实例中,第一聚合层110由熔点为约267℃的PC制成。
在另一实施方式中,第一聚合层110的材料可还包含改质剂(诸如,稳定剂、颜料及填充剂)以改变第一聚合层110的物理特性,例如,机械强度、颜色等。举例而言,可添加填充剂至第一聚合层110中,填充剂相对于第一聚合层110中聚合物总量的重量百分比(wt%)为约0.1wt%至约300wt%。再者,可非必要性地添加偶合剂(诸如,硅烷)至第一聚合层110中,以增强聚合物材料与改质剂(诸如,填充剂或颜料)之间的黏合。举例而言,偶合剂相对于第一聚合层110中聚合物总量的重量百分比可在约0.1wt%至约20wt%范围内。
在其它实施方式中,第一聚合层110的材料可还包含接枝剂,并借此导入具有化学反应性的极性或位点。举例而言,接枝剂可为丙烯酸或顺丁烯二酸酐。在某些实施例中,第一聚合层110的材料可还包含化学交联剂,例如有机过氧化物。有机过氧化物可例如为过氧化二异丙苯、1-双(叔丁基过氧基)-3,3,5-三甲基环己烷、a,a′-二(叔丁基过氧基)二异丙苯或其组合。举例而言,交联剂的重量百分比可约0.1wt%至约5wt%,其是以相对于第一聚合层110中的聚合物总量来计算。
在一些实施方式中,第一聚合层110的材料不经历UV老化及/或发热剂以防止原来聚合物中的链发生链切断的现象。在此等实施例中,第一聚合层110可提供令人满意的机械强度。
形成第一聚合层110的方法并无特殊限制。举例而言,可借由习知的挤压(extrusion)或压延(calendaring)方法形成第一聚合层110。在一实施例中,可非必要性地利用定向制程(orientation process)来改变第一聚合层110的表面性质或机械特性。在某些实施例中,第一聚合层110暴露于辐射之下(诸如,电子束)以促进第一聚合层110的交联反应。
第二聚合层120可提供耐候性的功能。第二聚合层120具有高于90℃的熔点,熔点是借由示差扫描热量分析仪来量测。第二聚合层120可由单一种聚合物或聚合体掺合物(polymer blend)制成。在一实施例中,第二聚合层120由以线性低密度聚乙烯(LLDPE)、低密度聚乙烯(LDPE)、中密度聚乙烯(MDPE)、高密度聚乙烯(HDPE)、聚碳酸酯(PC)或耐纶所制成。在某些实施例中,第一聚合层110可由聚合体掺合物制成,此聚合体掺合物含有至少一种上述的聚合物。举例而言,聚合体掺合物可为HDPE与其它等级的HDPE树脂、MDPE、LDPE或LLDPE掺混而组成。在某些实施例中,第二聚合层120的厚度为约0.05mm至约2mm,且第二聚合层120通常是直接暴露于周围环境中。在其它实施例中,第一聚合层及第二聚合层可由相同材料制成。本文所揭露的第二聚合层是由廉价的聚合物(诸如,PE、PC或耐纶)制成,因此可降低背层的制造成本。
在一些实施例中,第二聚合层120的材料可进一步包含改质剂(诸如,稳定剂、颜料及填充剂)以便修改第二聚合层120的物理特性,例如机械强度、颜色等。在一实施例中,可将相对于第二聚合层120中聚合物总量的约0.1wt%至约300wt%的填充剂添加至第二聚合层120中。在另一实施例中,可将诸如硅烷的偶合剂添加至第二聚合层120中,以增强聚合材料与改质剂(诸如,填充剂或颜料)之间的接合。举例而言,偶合剂的重量百分比为约0.1wt%至约20wt%,此重量百分比是以相对于第二聚合层120中聚合物总量来计算。
在其它实施例中,第二聚合层120的材料可还包含接枝剂,并借此导入具有化学反应性的极性或位点。举例而言,接枝剂可为丙烯酸或顺丁烯二酸酐。在某些实施例中,第二聚合层120的材料可还包含化学交联剂,诸如,有机过氧化物。有机过氧化物可例如为过氧化二异丙苯、1-双(叔丁基过氧基)-3,3,5-三甲基环己烷、a,a′-二(叔丁基过氧基)二异丙苯或其组合。举例而言,交联剂的重量百分比可约0.1wt%至约5wt%,其是以相对于第二聚合层120中的聚合物总量来计算。
在一些实施方式中,第一聚合层110的材料不经历UV老化及/或发热剂以防止原来聚合物中的链发生链切断的现象。在此等实施例中,第一聚合层110可提供令人满意的机械强度。
形成第二聚合层120的方法并无特殊限制。举例而言,可借由习知的挤压(extrusion)或压延(calendaring)方法形成第二聚合层120。在一实施例中,可非必要性地利用定向制程(orientation process)来改变第二聚合层120的表面性质或机械特性。在某些实施例中,第二聚合层120暴露于辐射之下(诸如,电子束)以促进第二聚合层120的交联反应。
水气阻层130可提供阻隔水气的功能,且配置在第一聚合层110与第二聚合层120之间。水气阻层130可为单层结构或多层结构。在一实施方式中,水气阻层130可由聚合物材料所制成。在一实施例中,水气阻层130可为聚偏二氯乙烯(PVDC)层或乙烯-乙烯醇共聚物(EVOH)层。在另一实施例中,水气阻层130可由PVDC层以及EVOH层组成的双层结构。在某些实施方式中,水气阻层130可由金属材料(诸如,铝或不锈钢)所制成。举例而言,水气阻层130可为借由溅镀制程所形成的铝层。或者,水气阻层130可为一铝箔。在某些实施例中,水气阻层130的厚度为约0.001mm至约2mm。
在一实施方式中,背层100可进一步包含第一黏着层140及第二黏着层150。如图1所示,第一黏着层140配置在第一聚合层110与水气阻层130之间,而第二黏着层150配置在第二聚合层120与水气阻层130之间。第一黏着层140的材料可相同于或不同于第二黏着层150的材料。举例而言,第一黏着层及/或第二黏着层可包含乙烯乙酸乙烯酯(EVA)或聚乙烯醇缩丁醛(PVB)。在一些实施例中,第一黏着层与第二黏着层的厚度为约0.01mm至约0.5mm。
在一实施例中,可借由以下步骤形成第一黏着层140:(1)形成一层水性或溶剂型黏着溶液于第一聚合层110(或水气阻层130)上;(2)在黏着溶液层上形成水气阻层130(或第一聚合层110);以及(3)将上述多层结构置入温度约80℃的环境中,以移除水或溶剂。移除水或溶剂的温度可为任何温度,只要在干燥时间内此温度不会使第一聚合层110或水气阻层130发生形变即可。在另一实施例中,可借由涂布熔融态的黏着剂来形成第一黏着层140,稍后再借由将一溶剂涂覆在黏着层140上使此熔融黏着剂再活化。也可利用上述方法在水气阻层130或第二聚合层120上形成第二黏着层150。
形成背层100的方法并无特殊限制。在一实施例中,可借由共挤压制程(co-extrusion process)同时将第一黏着层140与第一聚合层110两者涂布在水气阻层130的表面上。此后,再将第二黏着层150与第二聚合层120同时涂布在水气阻层130的相对表面上。因此,可制造出背层100。再者,可借由在水气阻层130的相对两面上同时共挤压第一黏着层/第一聚合层以及第二黏着层/第二聚合层,而以单一步骤形成背层100。
在一实施例中,可借由对第一聚合层110施加热量,而将背层100的第一聚合层110直接黏着至一太阳能电池,因为本发明所揭露的第一聚合层110为诸如PE或PC的热塑性聚合物。因此,不再需要额外的黏着剂,并因此可降低组装太阳能电池及背层所花费的操作成本。
虽然本发明已以实施方式揭露如上,然其并非用以限定本发明,任何本领域普通技术人员,在不脱离本发明的精神和范围内,当可作各种的更动与润饰,因此本发明的保护范围当视后附的权利要求书所界定者为准。
Claims (10)
1.一种用于太阳能模块的背层,其特征在于,包含:
一第一聚合层,包含至少一聚合物是选自由线性低密度聚乙烯、低密度聚乙烯、中密度聚乙烯、高密度聚乙烯及聚碳酸酯所组成的群组;
一第二聚合层,具有高于90℃的熔点,其是借由一示差扫描热量分析仪所量测,其中该第二聚合层包含至少一聚合物是选自由线性低密度聚乙烯、低密度聚乙烯、中密度聚乙烯、高密度聚乙烯、聚碳酸酯及耐纶所组成的群组;以及
一水气阻层,配置在该第一聚合层与该第二聚合层之间。
2.根据权利要求1所述的背层,其特征在于,该第一聚合层具有一相同于该第二聚合层的组成。
3.根据权利要求1所述的背层,其特征在于,该第一聚合层还包含至少一改质剂是选自由稳定剂、颜料、填充剂及偶合剂所组成的群组。
4.根据权利要求3所述的背层,其特征在于,该偶合剂包含硅烷。
5.根据权利要求1所述的背层,其特征在于,该第一聚合层还包含一接枝剂,且该接枝剂包含至少一丙烯酸以及顺丁烯二酸酐。
6.根据权利要求1所述的背层,其特征在于,该第一聚合层还包含一含有有机过氧化物的一化学交联剂。
7.根据权利要求6所述的背层,其特征在于,该有机过氧化物是选自由过氧化二异丙苯、1-双(叔丁基过氧基)-3,3,5-三甲基环己烷以及a,a′-二(叔丁基过氧基)二异丙苯所组成的群组。
8.根据权利要求1所述的背层,其特征在于,该第一聚合层由一聚合体掺合物制成。
9.根据权利要求1所述的背层,其特征在于,该水气阻层包含一聚合物是选自由聚偏二氯乙烯以及乙烯与乙烯醇共聚物所组成的群组。
10.根据权利要求1所述的背层,其特征在于,该水气阻层由铝或不锈钢制成。
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CN201199523Y (zh) * | 2008-08-29 | 2009-02-25 | 苏州中来太阳能材料技术有限公司 | 一种用于太阳能电池的背膜 |
CN101359695A (zh) * | 2008-09-02 | 2009-02-04 | 中国乐凯胶片集团公司 | 一种太阳能电池背板 |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN102544151A (zh) * | 2011-12-31 | 2012-07-04 | 苏州幸福新能源科技有限责任公司 | 新型太阳能背板用e膜 |
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