CN102376800A - 光伏部件的背板 - Google Patents
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Abstract
本发明涉及一种光伏部件的背板。此背板包括一耐候层、一绝缘层以及一第一粘着层。耐候层包含氯化聚乙烯,且氯化聚乙烯的重量至少为耐候层重量的50%。耐候层位于背板的最外侧表面。绝缘层用以防止光伏部件产生的电流经由背板漏电。第一粘着层配置在耐候层与绝缘层之间。
Description
技术领域
本发明涉及一种封装片材,并且尤其涉及一种光伏模块的背板。
背景技术
光伏电池,又称为太阳能电池,是一种将光能转换为电能的装置。相较于传统能源,太阳能电池具有许多优点。例如,太阳能电池产生电能时不会造成污染,且不需化石燃料。
通常,太阳能模块包括一个刚性且透明的保护前板(例如玻璃)以及一个后板或片材(一般称为背板)。前板及背板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劣化。
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,背板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的能力。背板的进一步考虑在于其成本必须是商业上可接受的。
在现有技术中公开了一种包括聚氟乙烯或其它氟化聚合物(如,聚乙烯-四氟乙烯或聚乙烯-氯三氟乙烯)的背板。然而,氟化聚合物通常是昂贵的。除氟化聚合物之外,用于背板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也被用作背板结构的一部分材料,该聚对苯二甲酸乙二酯必须经过昂贵的取向工艺来形成取向膜。此外,另一种用于柔性光伏模块的背板结构的聚酰亚胺也是昂贵的聚合物。因此,目前亟需一种成本更低的背板。
发明内容
本发明提供一种光伏部件的背板,该背板结构简单且制造成本低廉。
根据本发明一实施方式,此背板包括一耐候层、一绝缘层以及一第一粘着层。耐候层包含氯化聚乙烯,且该氯化聚乙烯的重量至少为耐候层重量的50%。绝缘层用以防止光伏部件产生的电流经由背板漏电。第一粘着层配置在耐候层与绝缘层之间。
在一实施方式中,上述背板还包括一阻水气层,该阻水气层配置在耐候层与绝缘层之间,且耐候层与阻水气层接触。
在一实施方式中,上述背板的阻水气层包含一选自聚偏二氯乙烯树脂以及乙烯-乙烯醇共聚物所组成群组的高分子材料。
在一实施方式中,上述氯化聚乙烯中的氯占氯化聚乙烯重量的至少25%。
在一实施方式中,上述耐候层还包括至少一改质剂,该改质剂选自由稳定剂、色素、填充物以及耦合剂所组成的群组。
在一实施方式中,上述氯化聚乙烯为丙烯酸接枝的氯化聚乙烯、磺酸酯接枝的氯化聚乙烯或马来酸酐接枝的氯化聚乙烯。
在一实施方式中,上述第一粘着层包含至少一选自乙烯-丙烯酸共聚物、乙烯-马来酸酐共聚物、乙烯-醋酸乙烯共聚物、聚乙烯醇缩丁醛以及两段式聚氨基甲酸酯所组成群组的材料。
在一实施方式中,上述氯化聚乙烯的重量至少为耐候层重量的70%。
根据本发明的另一方面,提供一种光伏模块,该光伏模块包括上述背板以及一配置在该背板上的光伏部件,其中背板的耐候层位于该光伏模块的一最外侧表面。
根据本发明的又一方面,提供一种用于光伏部件的背板,此背板不包含金属成分且实质上由一耐候层、一绝缘层以及一第一粘着层所组成,该耐候层包含氯化聚乙烯且位于该背板的一最外侧表面,该氯化聚乙烯在该耐候层的重量百分率至少为50%;该绝缘层用以防止该光伏部件产生的电流经由该背板漏电;该第一粘着层配置在该耐候层与该绝缘层之间。
附图说明
图1绘示根据本发明一实施方式的背板的剖面示意图。
图2绘示根据本发明另一实施方式的背板的剖面示意图。
图3绘示根据本发明一实施方式的光伏模块的剖面示意图。
具体实施方式
为了使本公开内容的叙述更加详尽与完备,下文针对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。以下所公开的各实施例,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,可在没有这些特定细节的情况下实践本发明的实施例。在其它情况下,为简化图式,已知的结构与装置仅示意性地绘示于图中。
以下公开一种用于光伏部件的背板。图1绘示根据本发明一实施方式的背板100的剖面示意图。如图1所示,背板100包括耐候层110、绝缘层120以及第一粘着层130。
耐候层110用以提供对于气候的阻抗性,因此可位于背板100的最外侧表面。耐候层110包含氯化聚乙烯,且氯化聚乙烯的重量至少为耐候层110重量的50%。例如,按耐候层110重量计,氯化聚乙烯的含量可为70%、80%、90%或95%。在一实施方式中,氯化聚乙烯中的氯占氯化聚乙烯重量的至少25%,具体而言,为约25%至约55%。在另一实施方式中,耐候层110的厚度大于约1μm,更具体地说,大于约10μm,更具体地说,大于约25μm。
含有氯化聚乙烯的耐候层110不仅提供气候阻抗的功能,还具有阻隔水气或湿气的功能。氯化聚乙烯层可呈现出约2-5克-密耳/(100平方英寸×天)的极佳的水气阻抗。因此,现有技术中可移除作为阻水气层的金属薄层,而使背板中不包含金属材料。在此公开的背板100可以应用在对于水气较不敏感的光伏模块,例如多晶硅光伏模块。在这些实施例中,耐候层110的厚度可大于约10μm,更具体地为大于25μm,更具体地为约50μm至约300μm;在上述这些厚度范围可以得到令人满意的水气阻抗特性。再者,在此公开的背板100是采用价格较便宜的高分子材料(即氯化聚乙烯),且具有一种不需要金属薄层的简单结构。因此,背板100是具成本效益的。
在一实施方式中,耐候层110还包括至少一种改质剂,例如稳定剂、色素或填充物,用以改变耐候层110的诸如机械强度、耐久性及颜色等物理性质。举例而言,以耐候层的总重量计算,约0.1wt%至约50wt%的改质剂可添加至耐候层110。更具体而言,约5%至约30%的改质剂添加入耐候层110中。在某些实施方式中,耐候层110可具有多层结构,其中配置有一层纯质的氯化聚乙烯。举例而言,一层纯质的氯化聚乙烯可被压合在另一层含有稳定剂、色素或填充物的氯化聚乙烯上。
在另一实施方式中,耐候层110中的氯化聚乙烯可以是内烯酸接枝的氯化聚乙烯、磺酸酯接枝的氯化聚乙烯或马来酸酐接枝的氯化聚乙烯,以便改变原本氯化聚乙烯的化学性质。具体而言,诸如丙烯酸、磺酸酯及马来酸酐等接枝剂可用以修饰耐候层110中氯化聚乙烯的分子结构。但本发明不限于上述接枝剂。
绝缘层120配置在耐候层110上方。一般而言,光伏部件位于靠近绝缘层120的一侧。绝缘层120用以防止光伏部件所产生的电流经由背板100而发生漏电现象。例如,绝缘层120可由诸如聚酯、聚亚酰胺、以及聚对苯二甲酸乙二酯等材料所制成。在某些实施例中,绝缘层120的厚度大于0.05mm,具体地说为大于0.1mm,更具体地说为大于0.2mm。
第一粘着层130配置在耐候层110与绝缘层120之间。第一粘着层130用以将耐候层110与绝缘层120连结在一起。在一实施方式中,第一粘着层130与绝缘层120及耐候层110相接触,如图1所示。在某些实施例中,第一粘着层130包含诸如乙烯-丙烯酸共聚物、乙烯-马来酸酐共聚物、乙烯-醋酸乙烯酯共聚物、聚乙烯醇缩丁醛(PVB)或两段式聚氨基甲酸酯(two-part polyurethane)等的至少一种高分子材料。在这些实施例中,第一粘着层130的厚度为约0.01mm至约0.5mm。
图2绘示根据本发明另一实施方式的背板200的剖面示意图。背板200包括如上所述的耐候层110、绝缘层120以及第一粘着层130,且还包括一阻水气层240。
阻水气层240提供防止水气渗透的功能,且配置在耐候层110与第一粘着层130之间。阻水气层240可由金属材料、高分子材料、无机材料或上述材料的组合所制成。在一实施例中,阻水气层240是由铝或不锈钢所制成,且耐候层110可直接与铝不锈钢层接触。耐候层110中的氯化聚乙烯与诸如铝箔的金属箔及不锈钢薄层之间具有极佳的粘着性。因此,不再需要现有技术中用来粘结阻水气层240与耐候层110的额外粘着层。具体而言,含有氯化聚乙烯的涂布流体(例如熔融的氯化聚乙烯、或氯化聚乙烯与溶剂的混合物)可以直接涂布在铝或不锈钢薄层上,而在铝或不锈钢薄层上形成耐候层110。在此公开的背板200采用了较便宜的高分子材料(即氯化聚乙烯),且不需要夹置在阻水气层240与耐候层110之间的粘着层,具有简单的结构。因此,根据本发明一实施方式的背板200是具成本效益的。
在某些实施例中,阻水气层240可例如由聚偏二氯乙烯树脂(PVDC)或乙烯-乙烯醇共聚物(EVOH)等高分子材料所制成。阻水气层240的厚度可例如为约1μm至约2000μm。
在背板200包括阻水气层240的实施方式中,耐候层110的厚度可减少至小于100μm的程度,更具体地为约1μm至约50μm。在此公开的含有阻水气层240的背板200可应用于对水气较敏感的光伏模块,例如非晶硅光伏模块。
在一实施方式中,背板200还包括第二粘着层260及连结层210,如图2所示。第二粘着层260配置在绝缘层120上,且位于第一粘着层130的相反侧。第二粘着层260是用以将绝缘层120与连结层210粘结在一起。第二粘着层260的材料可与第一粘着层130相同或不同。适当的第二粘着层材料包括但不限于乙烯-醋酸乙烯共聚物、聚乙烯醇缩丁醛、乙烯-丙烯酸共聚物、乙烯-马来酸酐共聚物以及两段式聚氨基甲酸酯。在这些实施例中,第二粘着层260的厚度在约0.01mm至约0.5mm的范围内。再者,连结层210可配置在第二粘着层260上,并用以连接至一光伏部件(图2未图示)。在某些实施例中,连结层210是由乙烯-醋酸乙烯共聚物所制成。
根据本发明的另一方面,公开了一种光伏模块。图3绘示根据本发明一实施方式的光伏模块300的剖面示意图。参见图3,光伏模块300包括光伏部件310以及背板320,背板320可为上述的任何实施方式或实施例。
在一实施方式中,背板320依序包括耐候层110、第一粘着层130、绝缘层120以及连结层210,耐候层110位于光伏模块300的最外侧表面。耐候层110、绝缘层120以及第一粘着层130可与前述实施方式相同。连结层210配置在绝缘层120上,如图3所示。
光伏部件310位于背板320的连结层210上。光伏部件310并无特殊限制,只要其可将光转换为电即可。一般而言,光伏部件310具有一入光面311以及一背表面312。光线313可穿透入光面311,然后被光伏部件310吸收。当光伏部件310吸收光,其中将产生电子-空穴对,然后,电子-空穴对被光伏部件310中内建的电场分离,并因此产生电流。光伏部件310的背表面312粘结至背板320的连结层210,而耐候层110则位于光伏模块300的最外侧表面。光伏部件310可为形成在聚亚酰胺或不锈钢基材上的柔性太阳能电池;或者光伏部件310可为形成在诸如玻璃的硬质基材上的刚性太阳能电池。在一实施例中,光伏部件310为一薄膜太阳能电池。在其它实例中,光伏部件310可以是形成在硅晶圆上的单晶硅太阳能电池或多晶硅太阳能电池。在某些实施例中,光伏部件310包含非晶硅,且具有由p型半导体、本征型导体、以及n型半导体所构成的p-i-n结构(未图示)。在其它实施例中,光伏部件310包含GaAs、CIGS或CdTe等材料。
虽然本发明已以实施方式公开如上,然而所述实施方式并非用以限定本发明,任何本领域技术人员,在不脱离本发明的精神和范围内,可作各种修改与改变,因此本发明的保护范围以权利要求为准。
Claims (10)
1.一种光伏部件的背板,包括:
一耐候层,该耐候层包含氯化聚乙烯,其中该氯化聚乙烯的重量至少为该耐候层重量的50%;
一绝缘层,用以防止该光伏部件产生的电流经由该背板漏电;以及
一第一粘着层,配置在该耐候层与该绝缘层之间。
2.如权利要求1所述的背板,还包括一阻水气层,该阻水气层配置在该耐候层与该绝缘层之间,且该耐候层与该阻水气层接触。
3.如权利要求2所述的背板,其中该阻水气层包含一高分子材料,该高分子材料选自聚偏二氯乙烯树脂以及乙烯-乙烯醇共聚物所组成的群组。
4.如权利要求1所述的背板,其中该氯化聚乙烯中的氯占该氯化聚乙烯重量的至少25%。
5.如权利要求1所述的背板,其中该耐候层还包括至少一改质剂,该改质剂选自由稳定剂、色素、填充物以及耦合剂所组成的群组。
6.如权利要求1所述的背板,其中该氯化聚乙烯为丙烯酸接枝的氯化聚乙烯、磺酸酯接枝的氯化聚乙烯或马来酸酐接枝的氯化聚乙烯。
7.如权利要求1所述的背板,其中该第一粘着层包含至少一选自乙烯-丙烯酸共聚物、乙烯-马来酸酐共聚物、乙烯-醋酸乙烯共聚物、聚乙烯醇缩丁醛以及两段式聚氨基甲酸酯所组成的群组的材料。
8.如权利要求1所述的背板,其中该氯化聚乙烯的重量至少为耐候层重量的70%。
9.一种光伏模块,包括:
如权利要求1所述的背板;以及
一配置在该背板上的光伏部件;
其中该背板的该耐候层位于该光伏模块的一最外侧表面。
10.一种光伏部件的背板,该背板不包含金属成分且实质上由下列组件所组成:
一耐候层,包含氯化聚乙烯,且位于该背板的一最外侧表面,该氯化聚乙烯在该耐候层的重量百分率至少为50%;
一绝缘层,用以防止该光伏部件产生的电流经由该背板漏电;以及
一第一粘着层,配置在该耐候层与该绝缘层之间。
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