CN102815070B - Solar cell back panel with improved cohesive property on packing materials - Google Patents

Solar cell back panel with improved cohesive property on packing materials Download PDF

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Publication number
CN102815070B
CN102815070B CN201110158393.5A CN201110158393A CN102815070B CN 102815070 B CN102815070 B CN 102815070B CN 201110158393 A CN201110158393 A CN 201110158393A CN 102815070 B CN102815070 B CN 102815070B
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sheet
fluoropolymer membrane
hot pressing
fluoropolymer
drawn
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CN102815070A (en
Inventor
刘泽琳
吴秋菊
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DuPont Electronics Inc
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EI Du Pont de Nemours and Co
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Priority to CN201110158393.5A priority Critical patent/CN102815070B/en
Priority to PCT/CN2012/076220 priority patent/WO2012167705A1/en
Priority to TW101120366A priority patent/TW201306286A/en
Publication of CN102815070A publication Critical patent/CN102815070A/en
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    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • 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
    • H01L31/04—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 adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/049—Protective back sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/14—Velocity, e.g. feed speeds
    • 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
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0825—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)

Abstract

The invention provides a solar cell back panel with improved cohesive property on packing materials and discloses hot-pressed fluoropolymer films or sheets and a manufacture method thereof. The manufacture method includes the following steps: (i) providing fluoropolymer films or sheets basically formed by fluoropolymers; (ii) performing hot pressing on the fluoropolymer films or sheets through a hot-pressing device, wherein the condition of the hot-pressing device is that the multilayer fluoropolymer films or sheets are pressed by the pressure of 0.01-50Kgf/cm<2> and heated at the temperature of about 160 DEG C-260 DEG C. The invention further discloses a solar cell module which comprises a back panel formed by the at least one layer of hot-pressed multilayer fluoropolymer films or sheets.

Description

Encapsulating material is had to the close-burning solar cell backboard of improvement
Technical field
The disclosure relates to a kind of close-burning fluoropolymer membrane or the sheet other polymeric material to improvement, and comprises the solar module of described fluoropolymer membrane or sheet.
Background technology
In solar module, the solar cell of electrical interconnection is encapsulated by front encapsulating material and rear encapsulating material usually, and the solar cell through encapsulation is then sandwiched between transparent header board and backboard further.The backboard of solar module is used as supporter and resists the barrier of environmental activity.In the backboard of prior art, due to its superior weatherability, mechanical performance, electric property and barrier property, those backboards (as having the backboard of polyvinyl fluoride/PET/polyvinyl fluoride (PVF/PET/PVF) sandwich construction) comprising fluoropolymer are widely used.But, a shortcoming of the backboard of such fluoropolymer is that the caking property between fluoropolymer membrane and encapsulating material (as ethylene/vinyl acetate (EVA)) can be deteriorated in time, and causes the delamination of solar module thus.So, still have and need exploitation to have the backboard containing fluoropolymer of good adhesion to encapsulating material.
disclosure
Object of the present disclosure is to provide a kind of method obtaining fluoropolymer membrane through hot pressing or sheet, the described fluoropolymer membrane through hot pressing or sheet have the adhesion strength improved polyolefin film, and described method comprises: (i) provides fluoropolymer membrane or the sheet of the drawn be substantially made up of fluoropolymer; (ii) by hot-press equipment, hot pressing is carried out to the fluoropolymer membrane of described drawn or sheet, the condition of described hot-press equipment is wherein set, be subject to 0.01-50Kgf/cm with the fluoropolymer membrane or sheet that make described drawn 2pressure and the heating of 160 DEG C-260 DEG C.
In an embodiment of described method, be arranged on the condition of the hot-press equipment used in step (ii), be subject to 0.1-50Kgf/cm with the fluoropolymer membrane or sheet that make described drawn 2, or preferred 0.5-50Kgf/cm 2, or more preferably 0.5-30Kgf/cm 2pressure, and 180 DEG C-260 DEG C or preferably 200 DEG C-260 DEG C or the more preferably heating of 200 DEG C-245 DEG C.
Described in another method embodiment in, the hot-press equipment used in step (ii) is paired flat plate heat, and by the fluoropolymer membrane of described drawn or sheet hot pressing 0.1-30 second between described flat plate heat, or preferred hot pressing 0.5-30 second, or more preferably hot pressing 0.5-20 second.
Described in another method embodiment in, the hot-press equipment used in step (ii) comprises at least one pair of mip rolls (nip roll) through heating, and the fluoropolymer membrane of described drawn or sheet by linear velocity be set to 0.01-100 m/min or preferably 0.1-50 m/min or more preferably described in 0.5-30 m/min at least one pair of through the mip rolls of heating.
Described in another method embodiment in, wherein before step (ii), the fluoropolymer membrane of described drawn or sheet are preheated to 160 DEG C-260 DEG C or preferably 180 DEG C-260 DEG C or more preferably 200 DEG C-260 DEG C or the also more preferably temperature of 200 DEG C-245 DEG C.Further, the fluoropolymer membrane of described drawn or sheet carry out preheating by infrared heating, air heat, flame heating, electron beam or laser; Or preferably, fluoropolymer membrane or the sheet of described drawn are heated by infra-red furnace.
Described in another method embodiment in, heat-press step (ii) is repeated 2-50 time, or preferably repeat 2-10 time.
Described in another method embodiment in, described fluoropolymer is selected from PVF, vinylidene, tetrafluoroethene, hexafluoropropene, the homopolymers of chlorotrifluoroethylene and copolymer, and the combination of two or more in them.Or described fluoropolymer is optional from polyvinyl fluoride, Kynoar and their combination; Or be preferably selected from polyvinyl fluoride.
The disclosure also provides by the fluoropolymer membrane through hot pressing prepared by above-mentioned arbitrary method or sheet.
In the fluoropolymer membrane of hot pressing or an embodiment of sheet, when the described fluoropolymer membrane through hot pressing or sheet are laminated to polyolefin film or sheet, adhesion strength between the fluoropolymer membrane through hot pressing recorded according to ASTM D903-38 or sheet and polyolefin film or sheet is at least 17N/cm, or be preferably at least 20N/cm, or be more preferably at least 40N/cm.In this embodiment, described polyolefin film or sheet can comprise polyolefin composition, and wherein said polyolefin composition comprises and is selected from following material: ethylene/vinyl acetate, ionomer, polyethylene, ethene/acrylic ester copolymer, acid copolymer and the combination of two or more in them; Or be preferably selected from ethylene/vinyl acetate.
The disclosure also provides multilayer fluoropolymer membrane or sheet, and it comprises the above-mentioned fluoropolymer membrane through hot pressing of at least one deck or sheet.Described multilayer fluoropolymer membrane or sheet can be the forms of duplicature or sheet, and wherein said duplicature or sheet are made up of through the fluoropolymer membrane of hot pressing or the polyester film of layer or sheet through fluoropolymer membrane or the sheet of hot pressing and being depressed into from level to level one deck substantially.Or, described multilayer fluoropolymer membrane or sheet can be the forms of trilamellar membrane or sheet, and wherein said trilamellar membrane or sheet to be two-layerly made up of through the polyester film between hot pressing fluoropolymer rete or lamella or sheet the two-layer fluoropolymer membrane through hot pressing or sheet and being pressed in from level to level substantially.In this embodiment, polyester film or sheet can form by being selected from following polyester substantially: PET, polybutylene terephthalate, polytrimethylene terephthalate, PEN, and the combination of two or more in them.
The disclosure also provides solar module, it backboard comprising one or more solar cell, be laminated to the rear encapsulated layer of rear surface of solar cell and be laminated to the rear encapsulated layer back side, wherein said rear encapsulated layer comprises polyolefin, and wherein said backboard comprises at least one deck above-described fluoropolymer membrane through hot pressing or sheet arbitrarily.
The disclosure also provides solar module, it backboard comprising one or more solar cell, be laminated to the rear encapsulated layer of rear surface of solar cell and be laminated to the rear encapsulated layer back side, wherein said rear case chip comprises polyolefin, and wherein said backboard comprises arbitrary the above multilayer fluoropolymer membrane or sheet.
In some embodiments of the above solar module, the polyolefin comprised in described rear encapsulated layer is selected from ethylene/vinyl acetate, ionomer, polyethylene, ethene/acrylic ester copolymer, acid copolymer, and the combination of two or more in them; Or the polyolefin preferably comprised in described rear encapsulated layer is selected from ethylene/vinyl acetate.
According to open, when the scope provided has two concrete end points, described scope should be understood and be included in any number between these two concrete end points, and be at or about one of any any number of these two endpoint values.
Detailed description of the invention
Disclosed herein is a kind of fluoropolymer membrane through hot pressing or sheet.The flat structure that the continuous print with homogeneous thickness is thin is referred at this term be used interchangeably " film " or " sheet ".Usually, sheet can have the thickness being greater than about 100 microns, and film can have about 100 microns or less thickness.According to the disclosure, obtained by following steps through the fluoropolymer membrane of hot pressing or sheet: (a) providing package containing or the fluoropolymer membrane of drawn that is substantially made up of fluoropolymer or sheet; (b) by fluoropolymer membrane or the sheet of hot-press equipment hot pressing drawn, the condition of described hot-press equipment is wherein set, is subject to about 0.01-50 kilogram/square centimeter (Kgf/cm with the fluoropolymer membrane or sheet that make drawn 2) pressure and the heating of about 160 DEG C-260 DEG C.
When a film or sheet are referred to " comprise or be substantially made up of (particular polymers) ", refer to that described film or sheet are made up of following material: (i) a kind of comprise the material of described particular polymers and other component or (ii) a kind of by described particular polymers and other component optionally specific, and adding of described other component specific can not bring side effect to the machinery of described film or sheet, physics and adhesive property.
Term " drawn " refers to drawing process as used herein, in this drawing process, polymer film or sheet on laterally and/or longitudinally by unidirectional or biaxial tension, to reach the combination of machinery and physical property.Must through being known in the art to the stretcher of the film of unidirectional or double stretching or sheet and method, and those skilled in the art suitably can change the method, to prepare film disclosed herein or sheet.The example of this equipment and method comprises as at United States Patent (USP) 3, and 278,663,3,337,665,3,456,044,4,590,106,4,760,116,4,769,421,4,797,235 and 4,886, disclosed those in 634.
The fluoropolymer membrane of drawn or sheet can comprise following fluoropolymer as used herein, or substantially form by being selected from following fluoropolymer: the homopolymers of PVF (VF), vinylidene (VDF), tetrafluoroethene (TFE), hexafluoropropene (HFP), chlorotrifluoroethylene (CTFE) and copolymer, and the combination of two or more in them.Exemplary fluoropolymer includes but not limited to polyvinyl fluoride (PVF), Kynoar (PVDF), ethene/chlorotrifluoroethylcopolymer copolymer (ECTFE), Tefzel (ETFE) more specifically as used herein, and the combination of two or more in them.
In one embodiment, the fluoropolymer membrane of drawn or sheet comprise PVF or the PVF film of drawn be substantially made up of PVF or sheet as used herein, and PVF has-(CH 2cHF) nthe thermoplastic fluoropolymer of-repetitive.It is prepared by any suitable method, as United States Patent (USP) 2, and 419, those methods disclosed in 010.Usually, PVF does not have the enough heat endurances for injection mo(u)lding, is therefore normally extruded by solvent or pouring procedure makes film or sheet.According to the disclosure, the PVF film of drawn or sheet are prepared by any suitable method, assist extrude as cast or solvent.Such as, United States Patent (USP) 2,953,818 disclose the extrusion method for preparing film from stretchable PVF, United States Patent (USP) 3,139,470 methods disclosing the PVF film for the preparation of drawn.
In addition, according to the disclosure, the fluoropolymer membrane of drawn or sheet also can comprise those through various surface-treated as used herein, to improve their adhesive properties to other film or sheet.Exemplary surface treatment includes but not limited to that chemical treatment (see such as United States Patent (USP) 3,122,445), flame treatment are (see such as United States Patent (USP) 3,145,242), and discharge process (see such as United States Patent (USP) 3,274,088).
The PVF film of drawn or sheet are also available commercially as used herein.Such as, the PVF film of suitable drawn or sheet can commercial name Tedlar purchased from American E.I.Du Pont De Nemours and Co. (E.I.duPont de Nemours and Company) (hereinafter referred to as " Du Pont ").
In another embodiment, the fluoropolymer membrane of drawn or sheet comprise PVDF or the pvdf membrane of drawn be substantially made up of PVDF or sheet as used herein, and PVDF has-(CH 2cF 2) nthe thermoplastic fluoropolymer of-repetitive.The pvdf membrane of commercially available drawn or sheet include but not limited to the Kynar from Arkema of the U.S. (Arkema Inc.) tMpvdf membrane, and from the Denka DX film of Japanese Denka electrochemically Co., Ltd. (Denka Group).
Hot-press method disclosed herein comprises the condition arranging hot-press equipment, is subject to about 0.01-50Kgf/cm to make described multilayer fluoropolymer membrane or sheet 2, or about 0.1-50Kgf/cm 2, or about 0.5-50Kgf/cm 2, or about 0.5-30Kgf/cm 2pressure, and the heating of about 160 DEG C-260 DEG C or about 180 DEG C-260 DEG C or about 200 DEG C-260 DEG C or about 200 DEG C-245 DEG C.As used herein " be subject to ... pressure " refer to the average pressure of described film or the certain force of sheet in its part by hot pressing suffered by per unit area.As used herein " be subject to ... heating " refer to when described film or sheet contact with the pressurized plane being heated to uniform temperature, described pressurized plane is to the heat applied by the part of hot pressing of described film or sheet.
Can use any suitable hot-press equipment at this, it can include but not limited to mip rolls, stack and flat-bed press.In those embodiments using flat plate heat, preferably the fluoropolymer sheet of described drawn or film are kept about 0.1-30 second under stress, or about 0.5-30 second, or about 0.5-20 second.Using in the mip rolls of heating or those embodiments of stack, the linear velocity of preferred roller machine is maintained at about 0.01-100 m/min, or about 0.1-50 m/min, or about 0.5-30 m/min.In addition, in some embodiments, described hot-press method also can comprise preheating step, wherein before heat-press step, by heating source, the fluoropolymer membrane of drawn or sheet is preheated to the temperature of about 160 DEG C-260 DEG C.Heating source can include but not limited to infrared (IR) heating (as infra-red furnace), air heat, flame heating, electron beam and laser etc. as used herein.Or, repeatedly hot pressing (2-50 time according to appointment, or about 2-10 time) can be carried out to the fluoropolymer membrane of described drawn or sheet.Such as, described hot-press method can comprise and the fluoropolymer membrane of described drawn or sheet repeatedly being suppressed between flat plate heat (2-50 time according to appointment, or about 2-10 time), wherein between each compacting, described film or sheet are cooled to room temperature.In addition, the fluoropolymer membrane of described drawn or sheet can at Multiple through then outs between the mip rolls or stack of heating, are cooled to room temperature between wherein preferably described film or sheet being passed through at each time.In one embodiment, by the fluoropolymer membrane of described drawn or sheet first (as by IR stove) be preheated to about 160 DEG C-260 DEG C, then it placed between paired flat plate heat and suppress about 0.1-30 second, wherein be arranged to the condition to flat plate heat, be subject to about 0.05-50Kgf/cm to make described film or sheet 2pressure and the heating of about 160 DEG C-260 DEG C.In another embodiment, first the fluoropolymer membrane of described drawn or sheet (as by IR stove) are preheated to the temperature of about 160 DEG C-260 DEG C, then make its by least one pair of through heating mip rolls between, wherein arranging at least one pair of linear velocity through the mip rolls of heating described is about 0.01-100 m/min, and other condition is set, is subject to about 0.05-50Kgf/cm to make described film or sheet 2pressure and the heating of about 160 DEG C-260 DEG C.In still another embodiment, the fluoropolymer membrane of described drawn or sheet Multiple through then out paired through heating mip rolls between (according to appointment 2-10 time), the linear velocity wherein arranging the described mip rolls through heating is in pairs about 0.01-100 m/min, and other condition is set, with make described film or sheet each time by process in be subject to about 0.05-50Kgf/cm 2pressure and the heating of about 160 DEG C-260 DEG C, and be cooled to room temperature between described film or sheet being passed through at each time.In still another embodiment, the fluoropolymer membrane of described drawn or sheet by multipair (according to appointment 2-10 to) between the mip rolls of heating, wherein arranging each linear velocity to the mip rolls through heating is about 0.01-100 m/min, and other condition is set, is subject to about 0.05-50Kgf/cm to make described film or sheet 2pressure and the heating of about 160 DEG C-260 DEG C, and, wherein the described multipair mip rolls through heating is separated, with make described film or sheet by described in lower a pair between the mip rolls of heating before can be cooled to room temperature.
The final gross thickness of the fluoropolymer membrane through hot pressing disclosed herein or sheet can be about 5-100 micron, or about 10-50 micron, or about 20-40 micron.
Embodiment as provided below confirms, when the fluoropolymer membrane through hot pressing disclosed herein or sheet are laminated to ethylene/vinyl acetate (EVA) sheet, through hot pressing fluoropolymer membrane or the adhesion strength between sheet and EVA sheet compared to not having very large improvement by the fluoropolymer membrane of the drawn of hot pressing or the adhesion strength between sheet and EVA sheet.Such as, when the fluoropolymer rete of the drawn by prior art or sheet are laminated to EVA sheet, the adhesion strength of itself and EVA sheet is only 10.1N/cm.But when in an identical manner (as above) being laminated to EVA sheet through the fluoropolymer rete of hot pressing or sheet, the adhesion strength of itself and EVA sheet can be increased to up to 78.3N/cm.
Therefore, according to the disclosure, when by when being laminated to polyolefin film or sheet (as EVA film or sheet) through the fluoropolymer membrane of hot pressing or sheet, the adhesion strength between the described fluoropolymer membrane through hot pressing or sheet and polyolefin film or sheet can reach at least about 17N/cm or at least about 20N/cm or the level at least about 40N/cm.
The disclosure also provides multilayer fluoropolymer membrane through lamination or sheet, and it comprises at least more than one deck disclosed fluoropolymer membrane through hot pressing or sheet, and one or more layers other extra layer.One or more layers other extra layer like this can by any suitable film or sheet as metal forming or polymeric membrane or sheet be formed.Can be formed by any suitable polymeric material except fluoropolymer in this polymeric membrane be suitable for or sheet.In one embodiment, described polymer film or sheet are polyester film or sheet as used herein, its (a) comprises polyester, or be substantially made up of polyester, or (b) comprises or substantially forms by being selected from following polyester: PET (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), PEN (PEN) and two or more combinations in them; Or (c) comprises or is substantially made up of PET.
In one embodiment, the described multilayer fluoropolymer membrane through lamination or sheet are the forms of double-deck fluoropolymer membrane through lamination or sheet, and it is made up of through the fluoropolymer membrane of hot pressing or sheet and a polyester film layer or sheet one deck substantially.In another embodiment, the described multilayer fluoropolymer membrane through lamination or sheet are the forms of three layers of fluoropolymer membrane through lamination or sheet, and it is made up of the polyester film layer be laminated between the two-layer fluoropolymer membrane through hot pressing or sheet or sheet substantially.When multilayer film or sheet being described as time " substantially by ... composition ", this refers to except listed component layers, states in multilayer film or sheet the close-burning adhesive that also can comprise or not comprise to improve between component layers in topic.
Through the multilayer fluoropolymer membrane of lamination or sheet by any suitable method as dry lamination or extruded type lamination are prepared.In addition, adhesive can be used between the adjacent layer of multilayer fluoropolymer membrane or sheet any pair, to improve adhesion strength therebetween.Suitable binding agent can include but not limited to polyurethanes, acrylic compounds, epoxies, TPO adhesive, and the combination of two or more in them.
The disclosure also provides solar module, it comprises one or more solar cell, is laminated to the rear encapsulated layer of described rear surface of solar cell, with the backboard being laminated to the described rear encapsulated layer back side, wherein said rear encapsulated layer comprises polyolefin, and wherein said backboard comprises the above-mentioned fluoropolymer membrane through hot pressing of at least one deck or sheet.
It can be any photoelectric conversion device that solar radiation can be converted to electric energy at this solar cell used.They can be formed by opto-electronic conversion body, and two interarea is formed with electrode.Described opto-electronic conversion body can be obtained by any suitable photoelectric conversion material, as crystalline silicon (c-Si), non-crystalline silicon (a-Si), microcrystal silicon (μ c-Si), cadmium telluride (CdTe), Cu-In selenide (CuInSe 2or CIS), copper indium/gallium diselenide (CuIn xga (1-x)se 2or CIGS), extinction dyestuff and organic semiconductor.Front electrode can by electrocondution slurry as silver paste be formed, and it is by any suitable printing process, as serigraphy or ink jet printing be coated on as described in opto-electronic conversion body front surface on.Front electrocondution slurry can comprise multiple parallel conduction grid line, and perpendicular to conduction grid line connected one or more conductive collecting bar, and back electrode is formed by metal paste being printed in the whole back surface of described opto-electronic conversion body.The suitable metal forming described back electrode includes but not limited to aluminium, copper, silver, gold, nickel, molybdenum, cadmium and their alloy.
In use, solar cell has usually before solar radiation (or on) surface, and back to the back of the body (or rear) face of solar radiation.Therefore, each component layers in solar module has front surface (or side) and the back side (or side).
According to the disclosure, the rear encapsulated layer being laminated to rear surface of solar cell can comprise polyolefin, and it includes but not limited to ethylene/vinyl acetate (EVA), ionomer, polyethylene, ethene/acrylic ester copolymer (such as ethylene/methyl acrylate copolymer and ethylene/butylacrylate copolymer), acid copolymer and the combination of two or more in them.In one embodiment, described rear encapsulated layer comprises EVA.As used herein based on the commercially available EVASKY from Japanese BRIDGESTONE company (Bridgestone) of encapsulated layer of EVA tM(commercial name); The Ultrapearl of Sandvik AB of Japan (Sanvic Inc.) tM(commercial name); The BixCure of U.S. Bixby International Corp. tM(commercial name); Or the Revax of Wenzhou Ruiyang Photovoltaic Material Co., Ltd. tM(Rui Fu) (commercial name).The exemplary encapsulated layer based on ionomer includes but not limited to the DuPont of Du Pont tMpV5300 series case chip and DuPont tMpV5400 series case chip.
In one embodiment, the backboard of solar module is formed by the above disclosed fluoropolymer membrane through hot pressing or sheet.In another embodiment, described backboard is formed by the above disclosed multilayer fluoropolymer membrane through lamination or sheet, and it comprises disclosed in more than at least one deck through the fluoropolymer membrane of hot pressing or sheet.
Solar module described herein also can comprise the transparent front encapsulated layer being laminated to described solar cell front surface, and is laminated to the transparent front plate of front surface of described front encapsulated layer further.
Suitable material for described transparent front encapsulated layer includes but not limited to the component comprising following material: EVA, ionomer, poly-(vinyl butyral) (PVB), polyurethane (PU), polyvinyl chloride (PVC), polyethylene, polyoJefin block elastomers, ethene/acrylic ester copolymer (as ethylene/methyl acrylate copolymer and ethylene/butylacrylate copolymer), acid copolymer, silicone elastomer, epoxy resin etc.
Any suitable glass or plastic sheet all can be used as described transparent front plate.Suitable material for plastic front sheet can include but not limited to glass, Merlon, acrylic resin, polyacrylate, cyclic polyolefin, ethene/norbornene copolymer, the polystyrene, polyamide, polyester, fluoropolymer etc. of metallocene catalysis and their combination.
Any suitable laminating method can be used to prepare solar module disclosed herein.In one embodiment, described method comprises: (a) provides the solar cell of multiple electrical interconnection; B () forms pre-laminated assembly, be wherein placed on rear encapsulated layer by solar cell, then places it on backboard, and wherein said backboard comprises the disclosed fluoropolymer membrane through hot pressing of more than at least one deck or sheet; (c) pre-laminated assembly described in lamination under heat and pressure.
In another embodiment, described method comprises: (a) provides the solar cell of multiple electrical interconnection; B () forms pre-laminated assembly, wherein solar cell is clipped between transparent front encapsulated layer and rear encapsulated layer, and then being clipped between transparent front plate and backboard, wherein said backboard comprises the disclosed fluoropolymer membrane through hot pressing of more than at least one deck or sheet; (c) pre-laminated assembly described in lamination under heat and pressure.
In one embodiment, use ICOLAM 10/08 laminating machine purchased from German Meier Solar Solutions GmbH, under about 135 DEG C-150 DEG C and about 1 atmospheric pressure, implement module laminating method be about 10-25 minute.
embodiment
the material used:
● PVF film: Tedlar the pvf film (thickness 38 microns) of PV2001 drawn, derives from Du Pont;
● EVA sheet: Revex tM767 (auspicious good fortune 767) Ethylene/vinyl acetate sheet (thickness 500 microns), derives from Wenzhou Ruiyang Photovoltaic Material Co., Ltd.;
● PET film: (both sides) are through the Melinex of sided corona treatment tMthe polyethylene terephthalate film (thickness 250 microns) of S drawn, derives from Dupont-Di Ren film company (DuPont Teijin Films).
comparative example CE1-CE2 and embodiment E 1-E7:
In CE1, following preparation has multiple laminate of " glass/EVA sheet/PVF film/PET film/PVF film " structure.First, Liofol LA 2692 polyurethane binder of 11: 1 ratios of use and curing agent UR7395 (all purchased from Henkel KGaA company (Henkel AG & Co.)), one deck PET film is laminated between the two-layer PVF film without hot pressing, to form " PVF film/PET film/PVF film " trilamellar membrane through lamination.Then, one deck EVA sheet (7 × 10cm) is placed on the thick sheet glass of one deck 3.2mm (7 × 10cm) and one deck between " PVF film/PET film/PVF film " trilamellar membrane (7 × 12cm) of lamination, to form the pre-laminate structure of multilayer, use ICOLAM 10/08 laminating machine, under 145 DEG C and 1 atmospheric pressure, vacuum lamination is carried out 15 minutes to it.In addition, before vacuum lamination processing, at the about half place along described pre-laminate structure length, a slice PEP (FEP) barrier film is placed between described EVA lamella and adjacent " PVF film/PET film/PVF film " trilamellar membrane layer.In this approach, after removing FEP barrier film, the trilamellar membrane layer of " PVF film/PET film/PVF film " will have the end loosened do not bondd with EVA sheet.Thereafter, length along each laminate cuts out two test-strips (2.54cm is wide and 12cm long), and use Instron 5566 tester (purchased from American Instron company), test the adhesion strength between EVA sheet and adjacent PVF film according to ASTM D903-98.Test the adhesion strength of all 6 test-strips prepared thus, calculate their mean value, the results list is in table 1.
In each embodiment of CE2 and E1-E7, substitute without except the PVF film of hot pressing in CE1 except using through the PVF film of hot pressing, multiplely to there is according to preparing with the same procedure described in CE1 the sheet through lamination of " glass/EVA sheet/through the PVF film/PET film/through the PVF film of hot pressing of hot pressing " structure substantially.By one deck PVF film being placed on infrared (IR) stove (model 10831010, purchased from Chinese Shanghai leap Medical Devices Co., Ltd.) middle a period of time, then make through heating PVF film by a pair through heating mip rolls, obtain the various PVF films through hot pressing used in each embodiment of CE2 and E1-E7.The preparation temperature of these various IR stoves used in the PVF film of hot pressing and the time of staying, temperature through the mip rolls of heating, the time of staying and pressure is listed in table 1.In addition, the same procedure by using in CE1 is determined in each embodiment of CE2 and E1-E7 in EVA sheet and adjacent adhesion strength between the PVF film of hot pressing.
Table 1
Remarks: 1in embodiment E 2 and E5, PVF film does not carry out mip rolls compacting by the heat treatment of IR stove;
2nA represents " inapplicable ";
3to survey adhesion strength be between EVA sheet and adjacent PVF film (being the PVF film through hot pressing in CE2 and E1-E7).
As above confirmed, contrast the adhesion strength (in CE1 for 10.1N/cm) of undressed PVF film and EVA sheet, the PVF film through hot pressing there is improvement with the adhesion strength (being 29.8-76.2N/cm in E1-E7) of EVA sheet.
comparative example CE3 and embodiment E 8-11:
In each embodiment of CE3 and E8-E11, substitute without except the PVF film of hot pressing in CE1 except using through the PVF film of hot pressing, multiplely to there is according to preparing with the same procedure described in CE1 the sheet through lamination of " glass/EVA sheet/through the PVF film/PET film/through the PVF film of hot pressing of hot pressing " structure substantially.Obtained the various PVF films through hot pressing used in each embodiment of CE3 and E8-11 by three roll coating production lines (model: KXE1222, purchased from American Davis-Standard LLC) by making described PVF film one or many.Between PVF film Multiple through then out three roll coating production line, at every turn by between described film is cooled to room temperature.List in table 2 for roller temperature, speed and the pressure set by three roll coating production lines.
According to the identical standard that uses in CE1, be determined at EVA sheet and the adjacent adhesion strength between the PVF film of hot pressing in each embodiment of CE3 and E8-E11, the results list is in table 2.
Table 2
1nA represents " inapplicable ";
2rT represents " room temperature ";
3to survey adhesion strength be between EVA sheet and PVF film (the PVF film through hot pressing in CE3 and E8-E16).
As above confirmed, contrast the adhesion strength (in CE1 for 10.1N/cm) of undressed PVF film and EVA sheet, that through the PVF of hot pressing there is improvement with adhesion strength (being 18.7-78.3N/cm in E8-E16) that is EVA sheet.

Claims (35)

1. one kind obtains the method for fluoropolymer membrane through hot pressing or sheet, the described fluoropolymer membrane through hot pressing or sheet have the adhesion strength improved polyolefin film, and described method comprises: (i) provides fluoropolymer membrane or the sheet of the drawn be substantially made up of fluoropolymer; (ii) by hot-press equipment, hot pressing is carried out to the fluoropolymer membrane of described drawn or sheet, the condition of described hot-press equipment is wherein set, be subject to 0.01-50Kgf/cm with the fluoropolymer membrane or sheet that make described drawn 2pressure and the heating of 160 DEG C-260 DEG C.
2. method according to claim 1, wherein in step (ii), arranges the condition of hot-press equipment, is subject to 0.1-50Kgf/cm with the fluoropolymer membrane or sheet that make described drawn 2pressure, and the heating of 180 DEG C-260 DEG C.
3. method according to claim 1, wherein in step (ii), arranges the condition of hot-press equipment, is subject to 0.5-50Kgf/cm with the fluoropolymer membrane or sheet that make described drawn 2pressure, and the heating of 200 DEG C-260 DEG C.
4. method according to claim 1, wherein in step (ii), arranges the condition of hot-press equipment, is subject to 0.5-30Kgf/cm with the fluoropolymer membrane or sheet that make described drawn 2pressure, and the heating of 200 DEG C-245 DEG C.
5. the method according to any one of claim 1-4, wherein said hot-press equipment is paired flat plate heat, and in step (ii), by the fluoropolymer membrane of described drawn or sheet hot pressing 0.1-30 second between described flat plate heat.
6. method according to claim 5, wherein said hot-press equipment is paired flat plate heat, and in step (ii), by the fluoropolymer membrane of described drawn or sheet hot pressing 0.5-30 second between described flat plate heat.
7. method according to claim 5, wherein said hot-press equipment is paired flat plate heat, and in step (ii), by the fluoropolymer membrane of described drawn or sheet hot pressing 0.5-20 second between described flat plate heat.
8. the method according to any one of claim 1-4, wherein said hot-press equipment comprise at least one pair of through heating mip rolls, and in step (ii), the fluoropolymer membrane of described drawn or sheet to be set to described in 0.01-100 m/min at least one pair of through the mip rolls of heating by linear velocity.
9. method according to claim 8, in step (ii), the fluoropolymer membrane of described drawn or sheet to be set to described in 0.1-50 m/min at least one pair of through the mip rolls of heating by linear velocity.
10. method according to claim 8, in step (ii), the fluoropolymer membrane of described drawn or sheet to be set to described in 0.5-30 m/min at least one pair of through the mip rolls of heating by linear velocity.
Method according to any one of 11. claim 1-4, wherein before step (ii), is preheated to the temperature of 160 DEG C-260 DEG C by the fluoropolymer membrane of described drawn or sheet.
12. methods according to claim 11, wherein before step (ii), are preheated to the temperature of 180 DEG C-260 DEG C by the fluoropolymer membrane of described drawn or sheet.
13. methods according to claim 11, wherein before step (ii), are preheated to the temperature of 200 DEG C-260 DEG C by the fluoropolymer membrane of described drawn or sheet.
14. methods according to claim 11, wherein before step (ii), are preheated to the temperature of 200 DEG C-245 DEG C by the fluoropolymer membrane of described drawn or sheet.
15. methods according to claim 11, wherein before step (ii), the fluoropolymer membrane of described drawn or sheet carry out preheating by infrared heating, air heat, flame heating, electron beam or laser.
16. methods according to claim 11, wherein before step (ii), fluoropolymer membrane or the sheet of described drawn are heated by infrared heating furnace.
Method according to any one of 17. claim 1-4, wherein repeats heat-press step (ii) 2-50 time.
18. methods according to claim 17, wherein repeat heat-press step (ii) 2-10 time.
Method according to any one of 19. claim 1-4, wherein said fluoropolymer is selected from PVF, vinylidene, tetrafluoroethene, hexafluoropropene, the homopolymers of chlorotrifluoroethylene and copolymer, and the combination of two or more in them.
20. methods according to claim 19, wherein said fluoropolymer is selected from polyvinyl fluoride, Kynoar and their combination.
21. methods according to claim 19, wherein said fluoropolymer is selected from polyvinyl fluoride.
22. 1 kinds of fluoropolymer membranes through hot pressing or sheet, it is by the method preparation according to any one of claim 1-21.
23. fluoropolymer membrane through hot pressing according to claim 22 or sheets, wherein when the described fluoropolymer membrane through hot pressing or sheet are laminated on polyolefin film or sheet, the adhesion strength between the described fluoropolymer membrane through hot pressing recorded according to ASTM D903-38 or sheet and described polyolefin film or sheet is at least 17N/cm.
24. fluoropolymer membrane through hot pressing according to claim 22 or sheets, wherein when the described fluoropolymer membrane through hot pressing or sheet are laminated on polyolefin film or sheet, the adhesion strength between the described fluoropolymer membrane through hot pressing recorded according to ASTM D903-38 or sheet and described polyolefin film or sheet is at least 20N/cm.
25. fluoropolymer membrane through hot pressing according to claim 22 or sheets, wherein when the described fluoropolymer membrane through hot pressing or sheet are laminated on polyolefin film or sheet, the adhesion strength between the described fluoropolymer membrane through hot pressing recorded according to ASTM D903-38 or sheet and described polyolefin film or sheet is at least 40N/cm.
26. fluoropolymer membrane through hot pressing according to claim 22 or sheets, wherein said polyolefin film or sheet comprise polyolefin composition, and wherein said polyolefin composition is selected from following material: ethylene/vinyl acetate, ionomer, polyethylene, ethene/acrylic ester copolymer, acid copolymer, and the combination of two or more in them.
27. fluoropolymer membrane through hot pressing according to claim 26 or sheets, wherein said polyolefin film or sheet comprise polyolefin composition, and wherein said polyolefin composition comprises ethylene/vinyl acetate.
28. 1 kinds of multilayer fluoropolymer membranes or sheet, it comprises the fluoropolymer membrane through hot pressing at least according to any one of one deck claim 22-27 or sheet.
29. multilayer fluoropolymer membrane according to claim 28 or sheets, it is the form of duplicature or sheet, and wherein said duplicature or sheet form through the fluoropolymer membrane of hot pressing or sheet and the polyester film layer be laminated on the described fluoropolymer membrane through hot pressing or sheet or sheet by described in one deck substantially.
30. multilayer fluoropolymer membrane according to claim 28 or sheets, it is the form of trilamellar membrane or sheet, and wherein said trilamellar membrane or sheet are made up of the two-layer described fluoropolymer membrane through hot pressing or sheet and the polyester film be pressed in from level to level between the described two-layer fluoropolymer rete through hot pressing or sheet or sheet substantially.
Multilayer fluoropolymer membrane described in 31. claims 29 or 30 or sheet, wherein said polyester film or sheet form by being selected from following polyester substantially: PET, polybutylene terephthalate, polytrimethylene terephthalate, PEN, and the combination of two or more in them.
32. 1 kinds of solar modules, it comprises one or more solar cell, is laminated to the rear encapsulated layer of described rear surface of solar cell, with the backboard being laminated to the described rear encapsulated layer back side, wherein said rear encapsulated layer comprises polyolefin, and wherein said backboard comprises the fluoropolymer membrane through hot pressing at least according to any one of one deck claim 22-27 or sheet.
33. 1 kinds of solar modules, it comprises one or more solar cell, is laminated to the rear encapsulated layer of described rear surface of solar cell, with the backboard being laminated to the described rear encapsulated layer back side, wherein said rear encapsulated layer comprises polyolefin, and wherein said backboard comprises multilayer fluoropolymer membrane according to any one of claim 28-31 or sheet.
Solar module described in 34. claims 32 or 33, the polyolefin comprised in wherein said rear encapsulated layer is selected from ethylene/vinyl acetate, ionomer, polyethylene, ethene/acrylic ester copolymer, acid copolymer and the combination of two or more in them.
35. solar modules according to claim 34, the polyolefin comprised in wherein said rear encapsulated layer is selected from ethylene/vinyl acetate.
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