CN102365756A - 太阳能电池组件用背面保护片及具有该保护片的太阳能电池组件 - Google Patents
太阳能电池组件用背面保护片及具有该保护片的太阳能电池组件 Download PDFInfo
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- CN102365756A CN102365756A CN2010800148140A CN201080014814A CN102365756A CN 102365756 A CN102365756 A CN 102365756A CN 2010800148140 A CN2010800148140 A CN 2010800148140A CN 201080014814 A CN201080014814 A CN 201080014814A CN 102365756 A CN102365756 A CN 102365756A
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Abstract
本发明涉及太阳能电池组件用背面保护片,其是在基体材料片的至少一侧表面上隔着聚氨酯类粘接剂层叠层热粘接性片而构成的太阳能电池组件用背面保护片,其中,热粘接性片含有颜料,聚氨酯类粘接剂层含有硅烷偶联剂。所述颜料优选为无机颜料或炭黑。
Description
技术领域
本发明涉及太阳能电池组件用背面保护片、以及具有所述太阳能电池组件用背面保护片的太阳能电池组件。
本申请基于2009年3月30日在日本提出的日本特愿2009-081037号申请要求优先权,在此援引其内容。
背景技术
作为将太阳的光能转化为电能的装置,太阳能电池组件作为不排放二氧化碳就可以发电的系统而备受瞩目。
图2是示出通常的太阳能电池组件的一个实例的简略剖视图。
该太阳能电池组件100基本上由下述各部分构成:由晶体硅、无定形硅等构成的太阳能电池单元104、对太阳能电池单元104进行封装的由电绝缘体构成的封装材料(填充层)103、叠层在封装材料103表面的表面保护片(前板)101、以及叠层在封装材料103背面的背面保护片(背板)102。需要说明的是,有时前板101的基体材料为玻璃板。
为了使太阳能电池组件具有可以耐受在户外及室内长期使用的耐候性和耐久性,保护太阳能电池单元104及封装材料103不受风雨、湿气、砂尘、机械冲击等影响,需要使太阳能电池组件的内部保持在与外部气体隔离的密闭状态。为此,要求太阳能电池组件用背面保护片102具有优异的耐候性、耐久性、耐湿热性。
以往,作为太阳能电池组件用背面保护片,开发了使用电绝缘性优异的聚对苯二甲酸乙二醇酯等聚酯膜而得到的太阳能电池组件用背面保护片,并且,为了改善耐候性这一列举出的使用聚酯膜时的缺点,公开了使用下述参考文献中提到的膜的背面保护片:配合有紫外线吸收剂的膜(参考专利文献1);规定了聚酯中环状低聚物量的膜(参考专利文献2、3);规定了聚酯的分子量的膜(参考专利文献4)等。此外,为了改善上述膜与通常使用乙烯-乙酸乙烯酯共聚物(EVA)的封装材料103之间的粘接性低的现象,还公开了利用粘接剂在上述膜上粘贴以EVA为主成分的热粘接性片而形成的背面保护片,并且使用聚酯类粘接剂作为上述粘接剂使用(参考专利文献5~7)。
现有技术文献
专利文献
专利文献1:日本特开2001-111073号公报
专利文献2:日本特开2002-100788号公报
专利文献3:日本特开2002-134771号公报
专利文献4:日本特开2002-26354号公报
专利文献5:日本特开2008-85294号公报
专利文献6:日本特开2007-320218号公报
专利文献7:日本特开2008-4691号公报
发明内容
发明要解决的问题
但是,就上述现有技术中公开的太阳能电池组件用背面保护片而言,通过聚氨酯类粘接剂及热粘接性片,将聚对苯二甲酸乙二醇酯等基体材料膜贴合在封装材料103上,但上述聚氨酯类粘接剂和热粘接性片之间的粘接性及耐湿热性并不充分,当太阳能电池组件长期在户外使用时,由于所述基体材料膜发生剥离,担心会导致该太阳能电池组件内的电路发生漏电或腐蚀。
本发明是鉴于上述情况而完成的,其目的在于提供一种太阳能电池组件用背面保护片、及具有该太阳能电池组件用背面保护片的太阳能电池组件,所述太阳能电池组件用背面保护片的耐候性、耐久性、及耐湿热性高,尤其是与封装材料之间的粘接性优异,使得太阳能电池单元可以稳定地长期使用。
解决问题的方法
本发明人等考虑到上述问题,并且为了解决上述问题而进行了深入的研究,结果完成了本发明。即,本发明涉及一种太阳能电池组件用背面保护片,其是在基体材料片的至少一侧表面上隔着聚氨酯类粘接剂层叠层热粘接性片而构成的太阳能电池组件用背面保护片,其中,所述热粘接性片含有颜料,所述聚氨酯类粘接剂层含有硅烷偶联剂。
此外,本发明涉及上述热粘接性片中含有的颜料为无机颜料或炭黑的上述太阳能电池组件用背面保护片。另外,本发明涉及具有上述太阳能电池组件用背面保护片的太阳能电池组件。
发明的效果
在本发明中,通过隔着含有硅烷偶联剂的聚氨酯类粘接剂层将含有颜料的热粘接性片叠层在基体材料片上,可以粘接性良好地将基体材料片和热粘接性片贴合,从而可以提供耐湿热性非常优异的太阳能电池组件用背面保护片。由此,可以提供具有作为背面保护片的阻隔特性、并能够防止太阳能电池组件内电路的漏电和腐蚀的太阳能电池组件用背面保护片。通过具有上述背面保护片作为太阳能电池组件的背面保护片,可以实现太阳能电池组件稳定地长期使用。
附图说明
[图1]是示出本发明的太阳能电池组件用背面保护片的实施方式的一个实例的简略剖视图。
[图2]是示出通常的太阳能电池组件的一个实例的简略剖视图。
符号说明
20太阳能电池组件用背面保护片
24基体材料片
26热粘接性片
28聚氨酯类粘接剂层
100太阳能电池组件
101前板(表面保护片)
102背板(背面保护片)
103封装材料
104太阳能电池单元
具体实施方式
针对本发明的太阳能电池组件用背面保护片的实施方式进行说明。
需要说明的是,所述实施方式是为了更好地理解发明的主旨而作出的具体说明,如没有特别指出,不对本发明有任何限定。
图1是示出本发明的太阳能电池组件用背面保护片的实施方式的一个实例的简略剖视图。
该实施方式的太阳能电池组件用背面保护片20形成为如下的叠层结构:隔着聚氨酯类粘接剂层28将热粘接性片26叠层在基体材料片24上。
在本发明的太阳能电池组件用背面保护片20中,聚氨酯类粘接剂层28可以由含有多元醇化合物、异氰酸酯化合物和硅烷偶联剂的聚氨酯类粘接剂形成。
在本发明中,作为上述聚氨酯类粘接剂所含有的多元醇化合物,只要是具有2个以上羟基的化合物即可,对其分子量及骨架等没有特别地限定,作为其具体例,可以列举:低分子多元醇类、聚醚多元醇、聚酯多元醇、其它多元醇、以及它们的混合多元醇等。
其中,作为低分子多元醇,具体可以列举:乙二醇、二乙二醇、丙二醇、二丙二醇、1,3-丁二醇、1,4-丁二醇、戊二醇、3-甲基-1,5-戊二醇、新戊二醇、己二醇、环己烷二甲醇、甘油、1,1,1-三羟甲基丙烷、1,2,5-己三醇、季戊四醇等低分子多元醇及山梨醇等糖类。
作为聚醚多元醇,具体可以列举:聚乙二醇、聚丙二醇、聚丙三醇、氧化乙烯/氧化丙烯共聚物、聚四氢呋喃、山梨醇类多元醇等。
作为聚酯多醇,可以举出例如:上述低分子多元醇类和/或芳香族二醇类与多元羧酸形成的缩聚物(缩聚类聚酯多元醇)、内酯类多元醇、具有双酚骨架的聚酯多元醇等。
作为形成上述缩聚类聚酯多元醇的多元羧酸,具体可以举出:戊二酸、己二酸、壬二酸、庚二酸、辛二酸、癸二酸、对苯二甲酸、间苯二甲酸、二聚酸、其它低分子羧酸、寡聚酸、蓖麻油、蓖麻油与乙二醇的反应产物等羟基羧酸等。
此外,作为上述内酯类多元醇,具体可以列举:丙内酯、戊内酯等的开环聚合物等。
此外,作为具有双酚骨架的聚酯多醇,可以列举:使用具有双酚骨架的二醇来代替上述低分子多元醇类而得到的缩聚类聚酯多元醇,或使用具有双酚骨架的二醇和低分子多元醇类而得到的缩聚类聚酯多元醇。具体来说,可以列举:由双酚A和蓖麻油得到的聚酯多元醇、由双酚A蓖麻油、乙二醇和丙二醇得到的聚酯多元醇等。
作为其它多元醇,具体可以举出:聚碳酸酯二醇、丙烯酸多元醇;聚丁二烯多元醇;经过加氢的聚丁二烯多元醇等在主链骨架中具有碳-碳键的聚合物多元醇;等。
在这些多元醇化合物中,出于耐热性、稳定性的理由,优选聚酯多元醇、聚酯多元醇、聚醚多元醇、聚碳酸酯二醇、丙烯酸多元醇、或由2官能以上的异氰酸酯实施了扩链而得到的聚酯聚氨酯多元醇、聚醚聚氨酯多元醇、聚碳酸酯聚氨酯二醇、丙烯酸聚氨酯多元醇。
在本发明中,作为上述聚氨酯类粘接剂中含有的异氰酸酯化合物,只要是分子内具有1个以上异氰酸酯基的化合物即可,没有特别限定,优选使用在分子内含有2个以上异氰酸酯基的多异氰酸酯化合物。具体来说,可以使用:2,4-甲苯二异氰酸酯、2,6-甲苯二异氰酸酯、4,4′-二苯甲烷二异氰酸酯、对苯二异氰酸酯、二甲苯二异氰酸酯、四甲基二甲苯二异氰酸酯、联甲苯胺二异氰酸酯、1,5-萘二异氰酸酯、三苯甲烷三异氰酸酯等芳香族多异氰酸酯;六亚甲基二异氰酸酯、三甲基六亚甲基二异氰酸酯、赖氨酸二异氰酸酯、降冰片烷二异氰酸甲酯(ノルボルナンジイソシアナ一トメチル)等脂肪族二异氰酸酯;1,4-反式环己烷二异氰酸酯、异佛尔酮二异氰酸酯、二(异氰酸根合甲基)环己烷等脂环式多异氰酸酯,此外,还可以使用这些异氰酸酯的改性体,例如,三聚异氰酸酯型、聚氨酯型等三官能以上的多官能异氰脲酸酯化合物。
在这些异氰酸酯化合物中,优选二甲苯二异氰酸酯、四甲基二甲苯二异氰酸酯、六亚甲基二异氰酸酯、三甲基六亚甲基二异氰酸酯、异佛尔酮二异氰酸酯,因为它们的耐候性优异。
形成本发明的聚氨酯类粘接剂层28的聚氨酯类粘接剂中所含有的异氰酸酯化合物可以单独使用1种,也可以组合使用2种以上,相对于上述聚氨酯类粘接剂中含有的多元醇100重量份,异氰酸酯化合物的总使用量优选为5~40重量份,更优选为10~30重量份,进一步优选为10~20重量份。
在本发明中,作为上述聚氨酯类粘接剂中含有的硅烷偶联剂,只要是以往公知的硅烷偶联剂即可,没有特别限定,可以举出:氨基硅烷、巯基硅烷、乙烯基硅烷、环氧基硅烷、甲基丙烯酸基硅烷、异氰酸酯基硅烷、酮亚胺基硅烷(ketimine silane)、烷氧基硅烷等。这些化合物中,为了提高该聚氨酯类粘接剂相对于热粘接性片的粘接性,优选3-环氧丙氧丙基三甲氧基硅烷、苯基三甲氧基硅烷、四乙氧基硅烷、3-乙酰氧基丙基三甲氧基硅烷、3-氨基丙基三甲氧基硅烷。
形成本发明的聚氨酯类粘接剂层的聚氨酯类粘接剂中所含有的硅烷偶联剂可以单独使用1种,或组合使用2种以上,相对于上述聚氨酯类粘接剂中含有的多元醇100重量份,硅烷偶联剂的总使用量优选为0.01~30重量份,更优选为0.05~10重量份,进一步优选为0.1~3重量份。
在本发明中,作为上述聚氨酯类粘接剂,除了上述多元醇化合物、异氰酸酯化合物及硅烷偶联剂之外,还可以根据需要配合例如:抗氧剂、紫外线吸收剂、抗水解剂、增粘剂、增塑剂、填充剂等添加剂。其中,为了抑制酯键的水解,优选添加碳化二亚胺化合物、唑啉化合物。此外,为了提高在涂敷、形成层时的操作效率,可以向上述聚氨酯类粘接剂中添加溶剂来调节粘度,例如,可以根据需要使用乙酸乙酯等酯类溶剂、甲乙酮等酮类溶剂、甲苯、二甲苯等芳香族烃类溶剂等对于异氰酸酯不具有活性的任意溶剂。
在本发明中,可以通过下述方法形成聚氨酯类粘接剂层28,即,在基体材料片24上涂布上述聚氨酯类粘接剂,并根据需要进行干燥、加热。
作为在基体材料片24上涂布上述聚氨酯类粘接剂的方法,没有特别限定。可以举出以往公知的方法,例如:刮刀涂布法、刮辊涂布法、刮棒涂布法、刮板涂布法、狭缝口模涂布法、凹版涂布法等,可以使用这些方法中的任何方法。
聚氨酯类粘接剂层28的厚度优选为1μm~50μm,更优选为3μm~30μm。
对于本发明的太阳能电池组件用背面保护片20而言,只要热粘接性片26是具有热粘接性的树脂片,并且含有颜料即可,没有特别限定。在此,热粘接性是指通过加热处理表现出粘接性的性质。作为该加热处理的温度,通常为50~200℃的范围,优选为85~180℃的范围。
在本发明中,作为热粘接性片26中含有的颜料,只要是以往公知的颜料即可,没有特别限定,但从通过增大与聚氨酯类粘接剂层28中含有的硅烷偶联剂之间的亲和性来提高密合性的观点来看,优选无机颜料及炭黑,可以举出例如:碳酸钙、氧化钛、二氧化硅、氧化锌、碳酸铅、硫酸钡等白色颜料;炭黑(槽法炭黑或炉法炭黑)、黑色氧化铁等黑色颜料;群青、普鲁士蓝等蓝色颜料;氧化铁红、镉红、钼橙等红色颜料;赋予金属光泽的金属粉颜料等。其中优选氧化钛、炭黑。另外,这些颜料优选由有机硅化合物等包覆及进行了表面处理的颜料,更优选使用通过该表面处理赋予了羟基、烷氧基等极性基团的颜料。
在本发明中,作为构成热粘接性片26的树脂,只要是能够以分散的状态含有上述颜料即可,没有特别限制,可以举出由以丙烯酸聚氨酯树脂、乙烯-乙酸乙烯酯共聚物(EVA)、聚乙烯醇缩丁醛(PVB)、乙烯-甲基丙烯酸共聚物、利用金属离子使乙烯-甲基丙烯酸共聚物的分子间交联的离子聚合物树脂、以及聚烯烃为主成分的聚合物形成的树脂等。其中,更优选以EVA、PVB为主成分的树脂,进一步优选以EVA为主成分的树脂。一般来说,大多数情况下封装材料103是由EVA形成的树脂,此时,通过使热粘接性片26为由以EVA为主成分的聚合物形成的树脂片,可以提高封装材料103和热粘接性片26之间的匹配性及粘接性。
通过如下方法形成热粘接性片26:相对于构成上述热粘接性片26的树脂100重量份,以上述热粘接性片26中所含的颜料为0.5~30重量份、优选为1~10重量份的比例进行混炼,并通过T模头法、或吹塑(inflation)法熔融挤出而形成热粘接性片26。作为热粘接性片26的厚度,可以根据热粘接性片26的种类来适当调节,通常优选该片的厚度为5~200μm的范围。更具体来说,在热粘接性片26是由EVA形成的片的情况下,从轻质性及电绝缘性等观点来看,优选该EVA片的厚度为10~200μm的范围,更优选为50~150μm的范围,最优选为80~120μm的范围。
作为本发明的太阳能电池组件用背面保护片20中的基体材料片24,可以使用树脂片、铝片等。
作为用作基体材料片24的树脂片,可以使用通常被用作太阳能电池组件用背面保护片的树脂片。作为这样的树脂片,可以使用例如:由聚乙烯、聚丙烯、聚苯乙烯、聚甲基丙烯酸甲酯、聚四氟乙烯、聚酰胺(尼龙6、尼龙66)、聚丙烯腈、聚氯乙烯、聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚萘二甲酸乙二醇酯(PEN)、聚甲醛、聚碳酸酯、聚苯醚、聚酯聚氨酯、聚(间亚苯基间苯二甲酰胺)、聚(对亚苯基对苯二甲酰胺)等聚合物形成的片。其中,从电绝缘性、耐热性、耐药品性、尺寸稳定性良好的观点来看,优选由聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚萘二甲酸乙二醇酯(PEN)形成的片,尤其优选PET片。
上述PET片优选具有耐水解性的PET片,已知低聚物含量少的物质具有耐水解性。作为具有耐水解性的PET片,可以举出Melinex 238(商品名,帝人杜邦薄膜株式会社制造)等。
作为树脂片的厚度,可以基于太阳能电池系统所要求的电绝缘性进行调节,通常,优选该片的厚度为10~300μm的范围。更具体来说,树脂片为PET片时,从轻质性及电绝缘性的观点来看,该PET片的厚度优选为30~250μm的范围,更优选为40~200μm的范围,进一步优选为50~150μm的范围。
此外,可以对树脂片实施用于提高耐候性、耐湿性等的表面改性处理。例如通过在PET上蒸镀二氧化硅(SiO2)、铝(Al)及氧化铝(Al2O3)等,可以提高该太阳能电池组件用背面保护片的耐候性、耐湿性等。需要说明的是,该二氧化硅、铝及氧化铝等蒸镀处理可以在树脂片的两面进行,也可以仅在任何一侧的面上进行。
在本发明的太阳能电池组件用背面保护片20中的基体材料片24为铝片的情况下,可以进一步提高该背面保护片的耐候性、耐湿热性。
作为用作基体材料片24的铝片,只要不损害本发明的效果即可,没有特别限制,优选将含有0.7~5.0质量%范围的铁的铝-铁合金制成为片状而得到的基体材料片,更优选将含有1.0~2.0质量%范围的铁的铝-铁合金制成为片状而得到的基体材料片,进一步优选将含有1.2~1.7质量%范围的铁的铝-铁合金制成为片状而得到的基体材料片。具体来说,可以举出划分成JISH4160中所规定的合金编号为8021的合金。作为该铝-铁合金形成为片状的产品,可以优选使用例如日本制箔株式会社制造的PACAL21(商品名)。此外,还可以同样优选使用SUMIKEIARUMIHAKU株式会社制造的BESPA(商品名)。
与使用纯铝制片的情况相比,通过使用含有上述范围内的铁的铝-铁合金片,可以提高太阳能电池组件用背面保护片20的水蒸气阻隔性、及轻质性。可认为其理由是:与通常的纯铝相比,含有上述范围内的铁的铝-铁合金的压延加工性优异,因此即使在加工成厚度为20μm以下的片时,也很少产生针孔(pinhole),从而可以抑制通过该针孔的气体的流通,其结果,可以提高使用了该铝-铁合金片的背面保护片的水蒸气阻隔性。此外,由于压延加工性优异,可以在保持水蒸气阻隔性的状态下,将其加工成与纯铝片相比更薄的片,其结果,使用了该铝-铁合金片的背面保护片的轻质性得到提高。
只要不损害本发明的效果,铝-铁合金片还可以含有铁以外的元素。可以举出例如:镁、锰、铜、硅、锌、及钛等。这些元素是在铝-铁合金的制作过程中不可避免地含有的元素,但通常只要是微量含量,则可以认为不损害本发明的效果。在此,作为微量含量,是指各元素的含量分别为0.5质量%以下的情况,更优选各元素的含量分别为0.3质量%以下的情况。
作为铝-铁合金片的厚度,只要不损害本发明的效果即可,没有特别限制,但从产生针孔的频率低(水蒸气阻隔性高)、及轻质性等观点来看,优选为30μm以下,更优选为20μm以下,最优选为5~10μm的范围。
在本发明的太阳能电池组件用背面保护片20中,对于隔着聚氨酯类粘接剂层28在基体材料片24上叠层热粘接性片26的方法而言,可以在基体材料片24上形成了聚氨酯类粘接剂层28,然后利用层压法使热粘接片26叠层。此外,为了提高其粘接性,可以对基体材料片24的聚氨酯类粘接层28一侧的面进行电晕处理及/或化学药品处理。
就本实施方式的太阳能电池组件用背面保护片20而言,隔着聚氨酯类粘接剂层28将热粘接性片26叠层在基体材料片24上,且所述热粘接性片26含有颜料,聚氨酯类粘接剂层28含有硅烷偶联剂,通过形成上述的构成,利用所述颜料和所述硅烷偶联剂之间的亲和力提高效果,可以牢固地将基体材料片24与热粘接性片26进行粘接。由此,可以防止由于基体材料片24的剥离而导致的耐候性、耐久性及耐湿热性等功能的降低,从而可以提供一种即使在户外长期使用也保持良好的粘接性、从而能够对太阳能电池组件进行保护的太阳能电池组件用背面保护片。
在上述实施方式的背面保护片20中,优选在基体材料片24的与聚氨酯类粘接剂层28相接触的面不同侧的面(基体材料片24的背侧)上设置氟树脂层(图中未示出)。通过设置该氟树脂层,可以提高本发明的太阳能电池组件用背面保护片的耐候性。
作为上述氟树脂层,只要是不损害本发明的效果、且含有氟的层即可,没有特别限制。可以是例如具有含氟聚合物的片,或者可以是涂布具有含氟聚合物的涂料而形成的涂膜。从为了使背面保护片轻质化而进一步使上述氟树脂层变薄的观点来看,优选涂布具有含氟聚合物的涂料形成的涂膜。
作为上述具有含氟聚合物的片,可以优选列举将例如以聚氟乙烯(PVF)、乙烯-三氟氯乙烯(ECTFE)或乙烯-四氟乙烯(ETFE)为主成分的聚合物加工为片状而得到的片。作为上述以PVF为主成分的聚合物,可以使用杜邦公司制造的Tedlar(商品名)。此外,作为上述以ECTFE作为主成分的聚合物,可以使用Solvay Solexis公司制造的Halar(商品名)。作为上述以ETFE为主成分的聚合物,可以使用旭硝子株式会社制造的Fluon(商品名)。
作为上述具有含氟聚合物的片的厚度,从耐候性及轻质化的观点来看,通常优选在5~200μm的范围,更优选在10~100μm的范围,最优选在10~50μm的范围。
作为上述具有含氟聚合物的涂料,只要是能够溶解在溶剂中或分散在水中并进行涂布的涂料即可,并无特别限定。
作为可以包含在上述涂料中的含氟聚合物,只要是不损害本发明的效果、且含有氟的聚合物即可,没有特别限制,优选能够溶解在上述涂料的溶剂(有机溶剂或水)中、且能够进行交联的含氟聚合物。作为该含氟聚合物优选的实例,可以举出:旭硝子株式会社制造的LUMIFLON(商品名)、Central硝子公司制造的CEFRALCOAT(商品名)、DIC公司制造的FLUONATE(商品名)等以三氟氯乙烯(CTFE)为主成分的聚合物类;大金工业株式会社制造的ZEFFLE(商品名)等以四氟乙烯(TFE)为主成分的聚合物类;杜邦公司制造的Zonyl(商品名)、大金工业株式会社制造的Unidyne(商品名)等具有氟代烷基的聚合物、及以氟代烷基单元为主成分的聚合物类。其中,从耐候性及颜料分散性等观点来看,更优选以CTFE为主成分的聚合物和以TFE为主成分的聚合物,其中最优选上述LUMIFLON(商品名)和上述ZEFFLE(商品名)。
上述LUMIFLON(商品名)是含有CTFE、多种特定的烷基乙烯基醚、羟基烷基乙烯基醚为主要结构单元的非晶性聚合物。像LUMIFLON(商品名)这样的含有羟基烷基乙烯基醚的单体单元的聚合物,在溶剂可溶性、交联反应性、基体材料密合性、颜料分散性、硬度及柔软性方面优异,因此优选。
上述ZEFFLE(商品名)是TFE和有机溶剂可溶性烯烃(炭化水素オレフイン)的共聚物,其中,在含有具有高反应性羟基的烯烃的情况下,在溶剂可溶性、交联反应性、基体材料密合性及颜料分散性方面优异,因此优选。
此外,作为可以包含在上述涂料中的含氟聚合物的实例,可以举出具有固化性官能团的氟代烯烃的聚合物,作为具体例,可以列举下述聚合物作为优选的实例:TFE、异丁烯、偏氟乙烯(VdF)、羟基丁基乙烯基醚及其它单体形成的共聚物、以及TFE、VdF、羟基丁基乙烯基醚及其它单体形成的共聚物。
另外,还可以在所述涂布液中添加能够与上述含氟聚合物共聚的单体,作为这样的单体,可以列举例如:乙酸乙烯酯、丙酸乙烯酯、丁酸丁酯、异丁酸乙烯酯、三甲基乙酸乙烯酯、己酸乙烯酯、叔碳酸乙烯酯(バ一サチツク酸ビニル)、月桂酸乙烯酯、硬脂酸乙烯酯、环己烷羧酸乙烯酯及苯甲酸乙烯酯等羧酸的乙烯酯类,甲基乙烯基醚、乙基乙烯基醚、丁基乙烯基醚及环己基乙烯基醚等烷基乙烯基醚类。
作为上述涂料,除了上述含氟聚合物之外,还可以含有交联剂、催化剂、及溶剂,另外,根据需要,还可以含有颜料及填充剂等无机化合物。
作为涂料中含有的溶剂,只要是不损害本发明的效果的溶剂即可,并没有特别限定,可以优选使用具有选自下述溶剂中的1种以上的溶剂:甲乙酮(MEK)、环己酮、丙酮、甲基异丁基酮(MIBK)、甲苯、二甲苯、甲醇、异丙醇、乙醇、庚烷、乙酸乙酯、乙酸异丙酯、乙酸正丁酯及正丁醇。其中,从涂料中含有成分的溶解性的观点来看,更优选上述溶剂为具有选自MEK或MIBK中的任何1种以上的溶剂。
作为可以在上述涂料中含有的颜料及填充剂,只要不损害本发明的效果即可,并无特别限定,可以列举例如:二氧化钛、炭黑、二氧化硅等。更具体而言,为了赋予耐久性,作为颜料和填充剂,优选经包覆及表面处理的金红石型二氧化钛Ti-Pure R105(商品名,杜邦公司制造)、及经过二甲基聚硅氧烷的表面处理对二氧化硅表面的羟基进行了改性的疏水性二氧化硅CAB-O-SIL TS 720(商品名,Cabot公司制造)。
为了提高耐候性、耐擦伤性,上述涂膜优选通过交联剂固化。作为交联剂,只要是不损害本发明效果的交联剂即可,并无特别限定,作为优选使用的交联剂,可以列举:金属螯合物类、硅烷类、异氰酸酯类及三聚氰胺类。假定太阳能电池组件用背面保护片在户外使用30年以上的情况下,从耐候性的观点考虑,优选使用脂肪族的异氰酸酯类作为交联剂。
就上述涂料的组成而言,只要不损害本发明的效果即可,没有特别限定,例如作为以上述LUMIFLON作为基础物质的涂料组合物,可以举出将LUMIFLON(商品名)、颜料、交联剂、溶剂及催化剂混合而得到的组合物。作为其组成比,将涂料总量作为100质量%时,LUMIFLON(商品名)优选为3~80质量%、更优选为10~40质量%左右;颜料优选为5~60质量%、更优选为10~30质量%左右;有机溶剂优选为20~80质量%、更优选为30~70质量%左右。
作为上述有机溶剂,可以列举MEK、二甲苯和环己酮的混合溶剂。此外,作为上述催化剂,可以列举二丁基二月桂酸锡、二辛基二月桂酸锡,上述催化剂用来促进LUMIFLON(商品名)和异氰酸酯在有机溶剂中的交联。
作为将上述涂料涂布在与基体材料片24和聚氨酯类粘接剂层28相接触的面不同的面一侧上的方法,可以利用公知的方法来进行,例如可以利用棒涂机涂布成所期望的膜厚。
对于上述涂料固化而形成的上述氟树脂层的膜厚,没有特别限定,例如可以形成为5μm以上的膜厚。从水蒸气阻隔性、耐候性及轻质性的观点来看,作为该氟树脂层的膜厚,优选为5~50μm,更优选为8~40μm,进一步优选为10~30μm。
就上述已涂布的涂料的干燥工艺的温度而言,只要是不损害本发明效果的温度即可,从促进交联及降低基体材料片24的热形变的观点来看,优选为50~130℃左右的范围。
本发明的太阳能电池组件用背面保护片可以与用于形成太阳能电池组件的传统公知的材料组合,由此制成太阳能电池组件使用。
例如,如图2所示,本发明的太阳能电池组件由以下部分构成:由晶体硅、无定形硅等形成的太阳能电池单元104、对太阳能电池单元104进行封装的由电绝缘体构成的封装材料(填充层)103、叠层在封装材料103表面的表面保护片(前板)101、以及叠层在封装材料103背面的背面保护片(背板)102。
作为封装材料103,可以使用以乙酸乙烯酯-乙烯共聚物(EVA)、聚乙烯醇缩丁醛、有机硅树脂、环氧树脂、氟代聚酰亚胺树脂、丙烯酸类树脂、聚酯树脂等透明树脂为主成分的树脂。这些树脂可以单独使用,也可以混合2种以上使用。
通过将本发明的太阳能电池组件用背面保护片20作为图2中的背面保护片102使用,并将其叠层在由内包有太阳能电池单元104的封装材料103形成的封装面上,可以保护该太阳能电池组件内的太阳能电池单元104及封装材料103不受风雨、湿气、砂尘、机械冲击等影响,保持该太阳能电池组件的内部处在与外部气体隔离的密闭状态。
在将本发明的太阳能电池组件用背面保护片叠层在封装面上的情况下,是将太阳能电池组件用背面保护片中的热粘接性片叠层在封装面上。作为其叠层方法,可以使用公知的方法。
在上述实施方式中,举例说明了基体材料片24、聚氨酯类粘接剂层28及热粘接性片26分别叠层了1层的太阳能电池组件用背面保护片,但本发明的太阳能电池组件用背面保护片并不限于此。对于本发明的太阳能电池组件用背面保护片而言,也可以是基体材料片、聚氨酯类粘接剂层和/或氟树脂层多层叠层而形成的结构。
实施例
以下,结合实施例及比较例对本发明进行更为具体的说明,但本发明并不限于下述实施例。
(热粘接性片1的形成)
将100重量份的Evaflex V5961(三井杜邦聚合化学株式会社制造,乙烯乙酸乙烯酯共聚物,乙烯∶乙酸乙烯酯=91∶9)和6.0重量份作为颜料的二氧化钛GTR-300(堺化学工业株式会社制造)混合,使用T模头制膜机Laboplastomill(东洋精机制作所株式会社制造),在机筒温度220℃、T模头温度220℃时熔融挤出,使得制成的膜的膜厚为100μm、宽度为300mm,由此形成了热粘接性片1。
(热粘接性片2的形成)
将100重量份的Evaflex V5961(三井杜邦聚合化学株式会社制造,乙烯乙酸乙烯酯共聚物、乙烯∶乙酸乙烯酯=91∶9)和1.5重量份作为颜料的炭黑MA230(三菱化学株式会社制造)混合,使用T模头制膜机Laboplasto mill(东洋精机制作所株式会社制造),在机筒温度220℃、T模头温度220℃时熔融挤出,使得制成的膜的膜厚为100μm、宽度为300mm,由此形成了热粘接性片2。
(热粘接性片3的形成)
对于Evaflex V5961(三井杜邦聚合化学株式会社制造,乙烯-乙酸乙烯酯共聚物,乙烯∶乙酸乙烯酯=91∶9),使用T模头制膜机Laboplasto mill(东洋精机制作所株式会社制造),在机筒温度220℃、T模头温度220℃时熔融挤出,使得制成的膜的膜厚为100μm、宽度为300mm,由此形成不含颜料的热粘接性片、即热粘接性片3。
实施例1
将100重量份的TAKELAC A-515(三井化学株式会社制造,聚酯多元醇,固体成分60%)和11.1重量份的TAKENATE A-50(三井化学株式会社制造,二甲苯二异氰酸酯,固体成分75%)混合,得到混合物,并向其中添加2.2重量份作为硅烷偶联剂的3-环氧丙氧丙基三甲氧基硅烷,并进一步添加278.3重量份的乙酸乙酯并进行混合,由此制备了聚氨酯类粘接剂。
接着,使用棒涂机,在作为基体材料片的PET膜即Melinex S(帝人杜邦薄膜株式会社制造,厚度125μm)的一侧表面上涂敷上述聚氨酯类粘接剂,并使得干燥涂膜厚度为5μm,在80℃干燥1分钟,从而形成了聚氨酯类粘接剂层。在常温下将上述热粘接性片1叠层在所得到的聚氨酯类粘接剂层上,在23℃、50%RH的环境中静置7天,由此得到了太阳能电池组件用背面保护片。
对于所制作的太阳能电池组件用背面保护片,通过下述方法,在促进试验条件下进行了粘接强度评价。结果如表1所示。
(促进试验)
将制作的太阳能电池组件用背面保护片切成A4大小,在85℃、85%RH的环境中静置500小时、1000小时、1500小时及2000小时。
(粘接强度评价)
按照ISO 11339标准,使用T形剥离法对剥离粘接强度进行了评价。将太阳能电池组件用背面保护片切成宽25mm、长150mm,将利用粘接剂贴合的基体材料片和热粘接性片分别固定在拉伸试验机(岛津制作所株式会社制造,Autograph AG-50kNX)上下的夹子上,测定了在23℃、50%RH的环境下、以300mm/min的剥离速度剥离时的剥离粘接强度(N/25mm)。该数值越大,表示粘接强度越大。
实施例2~6、及比较例1、2
将100重量份的TAKELAC A-515(三井化学株式会社制造,聚酯多元醇,固体成分60%)和11.1重量份的TAKENATE A-50(三井化学株式会社制造,二甲苯二异氰酸酯,固体成分75%)混合,得到混合物,向该混合物中添加2.2重量份表1所示的硅烷偶联剂,并进一步添加278.3重量份的乙酸乙酯,并进行混合,由此制备了聚氨酯类粘接剂。
接着,使用棒涂机,在作为基体材料片的PET膜即Melinex S(帝人杜邦薄膜株式会社制造,厚度125μm)的一侧表面上涂敷上述聚氨酯类粘接剂,并使得干燥涂膜厚度为5μm,在80℃干燥1分钟,从而形成了聚氨酯类粘接剂层。在常温下将上述表1所示的热粘接性片叠层在所得到的聚氨酯类粘接剂层上,并且在23℃、50%RH的环境中静置7天,由此得到了太阳能电池组件用背面保护片。
对于制作的太阳能电池组件用背面保护片,按照与实施例1相同的方法,在促进试验条件下进行了粘接强度评价。结果如表1所示。
[表1]
表1中的符号分别表示以下物质。
A-1:3-环氧丙氧丙基三甲氧基硅烷
A-2:苯基三甲氧基硅烷
A-3:四乙氧基硅烷
A-4:3-乙酰氧基丙基三甲氧基硅烷
A-5:3-氨基丙基三甲氧基硅烷
B-1:上述热粘接性片1
B-2:上述热粘接性片2
B-3:上述热粘接性片3
由表1的结果可确认:与比较例1和2相比,涉本发明的太阳能电池组件用背面保护片的实施例1~6即使在高温多湿的促进试验条件下,也显示良好的粘接强度。该结果说明:本发明的太阳能电池组件用背面保护片具有优异的耐湿热性和粘接性。
实施例7~11及比较例3
将100重量份的TAKELAC A-515(三井化学株式会社制造,聚酯多元醇,固体成分60%)和11.1重量份的TAKENATE A-50(三井化学株式会社制造,二甲苯二异氰酸酯,固体成分75%)混合,得到混合物,向该混合物中添加2.2重量份表2所示的硅烷偶联剂,并进一步添加278.3重量份的乙酸乙酯,并进行混合,由此制备了聚氨酯类粘接剂。
接着,使用棒涂机,在低聚物含量少的PET膜即Melinex 238(帝人杜邦薄膜株式会社制造,厚度125μm)的一侧表面上涂敷上述聚氨酯类粘接剂,并使得干燥涂膜厚度为5μm,在80℃干燥1分钟,从而形成乐聚氨酯类粘接剂层。在常温下将上述热粘接性片1叠层在所得到的聚氨酯类粘接剂层上,并且在23℃、50%RH的环境中静置7天,由此得到了太阳能电池组件用背面保护片。
在121℃、100%RH、2atm的条件下对所制作的太阳能电池组件用背面保护片进行保存,并按照与上述实施例1相同的方法,测定了保存24小时、48小时、96小时后粘接强度随保存时间的变化。结果如表2所示。
[表2]
表2中的符号分别表示以下物质。
A-1:3-环氧丙氧丙基三甲氧基硅烷
A-2:苯基三甲氧基硅烷
A-3:四乙氧基硅烷
A-4:3-乙酰氧基丙基三甲氧基硅烷
A-5:3-氨基丙基三甲氧基硅烷
由表2的结果可确认:与比较例3相比,涉及本发明的太阳能电池组件用背面保护片的实施例7~11即使在高温多湿的促进试验条件下,也显示良好的粘接强度。该结果说明:本发明的太阳能电池组件用背面保护片具有优异的耐湿热性和粘接性。
工业实用性
在本发明中,通过隔着聚氨酯类粘接剂层将含有颜料的热粘接性片叠层在含有硅烷偶联剂的基体材料片上,可以粘接性良好地将基体材料片和热粘接性片贴合,从而可以提供耐湿热性非常优异的太阳能电池组件用背面保护片。由此,可以提供具有作为背面保护片的阻隔特性、并能够防止太阳能电池组件内电路的漏电和腐蚀的太阳能电池组件用背面保护片。通过设置上述背面保护片作为太阳能电池组件的背面保护片,可以实现太阳能电池组件稳定的长期使用。
Claims (3)
1.一种太阳能电池组件用背面保护片,其是在基体材料片的至少一侧表面上隔着聚氨酯类粘接剂层叠层热粘接性片而构成的太阳能电池组件用背面保护片,其中,
所述热粘接性片含有颜料,所述聚氨酯类粘接剂层含有硅烷偶联剂。
2.根据权利要求1所述的太阳能电池组件用背面保护片,其中,所述热粘接性片中含有的颜料为无机颜料或炭黑。
3.一种太阳能电池组件,其具有权利要求1或2所述的太阳能电池组件用背面保护片。
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- 2010-03-19 CN CN2010800148140A patent/CN102365756A/zh active Pending
- 2010-03-19 EP EP10761335.8A patent/EP2416379A4/en not_active Withdrawn
- 2010-03-19 WO PCT/JP2010/001975 patent/WO2010116627A1/ja active Application Filing
- 2010-03-19 KR KR1020117022999A patent/KR101347547B1/ko not_active IP Right Cessation
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
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CN102938427A (zh) * | 2012-11-27 | 2013-02-20 | 宁波贝达新能源科技有限公司 | 一种光伏电池组件 |
CN102965549A (zh) * | 2012-11-27 | 2013-03-13 | 宁波贝达新能源科技有限公司 | 光伏电池组件用背板材料 |
CN102965549B (zh) * | 2012-11-27 | 2014-12-03 | 宁波贝达新能源科技有限公司 | 光伏电池组件用背板材料 |
CN102938427B (zh) * | 2012-11-27 | 2015-03-25 | 宁波贝达新能源科技有限公司 | 一种光伏电池组件 |
TWI800190B (zh) * | 2021-12-30 | 2023-04-21 | 欣興電子股份有限公司 | 玻璃載板保護結構及其製法 |
Also Published As
Publication number | Publication date |
---|---|
EP2416379A4 (en) | 2013-11-27 |
US20120034460A1 (en) | 2012-02-09 |
EP2416379A1 (en) | 2012-02-08 |
KR101347547B1 (ko) | 2014-01-10 |
WO2010116627A1 (ja) | 2010-10-14 |
JP2010232588A (ja) | 2010-10-14 |
KR20110123276A (ko) | 2011-11-14 |
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