CN103840023B - 模块结构 - Google Patents
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- CN103840023B CN103840023B CN201310350531.9A CN201310350531A CN103840023B CN 103840023 B CN103840023 B CN 103840023B CN 201310350531 A CN201310350531 A CN 201310350531A CN 103840023 B CN103840023 B CN 103840023B
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- 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
- B32B17/10009—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 number, the constitution or treatment of glass sheets
- B32B17/10018—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 number, the constitution or treatment of glass sheets comprising only one glass sheet
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- 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
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- 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
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Abstract
本发明提供模块结构，包括：前板；背板；光电组件，设于前板与背板之间；以及第一封装层，设于光电组件与前板之间，其中背板是氢化苯乙烯弹性体树脂层与聚烯烃层组成的层状结构，且氢化苯乙烯弹性体树脂层设于光电组件与聚烯烃层之间。
Description
技术领域
本发明关于模块结构，更特别关于其背板组成。
背景技术
一般太阳能电池模块结构，由上而下依序为玻璃前板、乙烯-醋酸乙烯酯共聚物(EVA)封装膜、太阳能电池、乙烯-醋酸乙烯酯共聚物封装膜、及背板。两个乙烯-醋酸乙烯酯共聚物封装膜的作用是固定太阳能电池、连接电路导线、作为电池的绝缘保护、以及在长年使用后维持太阳能电池的性能。背板可提供电性绝缘、阻水、及耐高温高湿度，以延长太阳能电池模块结构的使用寿命。
目前的背板主要由氟系树脂薄膜与聚对苯二甲酸乙二醇酯(PET)薄膜组成，因考量透水率或其它性质，常需在PET薄膜两侧涂布氟系树脂薄膜，有时考量氟系树脂薄膜与乙烯-醋酸乙烯酯共聚物封装膜之间的接着力，而涂布接着剂。
综上所述，发展新的背板结构是时势所趋。
发明内容
本发明一实施例提供的模块结构，包括：前板；背板，与前板相对设置；光电组件，设于前板与背板之间；以及第一封装层，设于光电组件与前板之间，其中背板为氢化苯乙烯弹性体树脂层与聚烯烃层组成的层状结构，且氢化苯乙烯弹性体树脂层设于光电组件与聚烯烃层之间。
图式简单说明
第1图为本发明一实施例中，模块结构的示意图；以及
第2图为本发明另一实施例中，模块结构的示意图。
符号说明
11前板
13、17封装层
15光电组件
19背板
19A氢化苯乙烯弹性体树脂层
19B聚烯烃层
实施方式
第1图为本发明一实施例中模块结构的示意图，由上而下依序为前板11、封装层13、光电组件15、封装层17、及背板19。前板11可为玻璃、乙烯-四氟化乙烯共聚物(ethylenetetrafluoroethylene,ETFE)、或聚丙烯酸酯等透明材质。在本发明一实施例中，封装层13与17可为乙烯-醋酸乙烯酯共聚物。如第1图所示，背板19为氢化苯乙烯弹性体树脂层19A与聚烯烃层19B组成之双层结构，且氢化苯乙烯弹性体树脂层19A设于封装层17与聚烯烃层19B之间。与习知背板中的PET薄膜相比较，聚烯烃层19B具有良好的低吸水性、耐水解性、电气绝缘性、与耐候性。聚烯烃层19B与封装层17之间，可采用氢化苯乙烯弹性体树脂层19A作为黏着层。在一实施例中，聚烯烃层19B可不需额外的保护膜如氟系树脂薄膜贴覆其下。另一方面，聚烯烃层19B与氢化苯乙烯弹性体树脂层19A可为共挤出成型的双层结构，能大幅节省工艺步骤与时间。
在本发明一实施例中，光电组件15为太阳能电池。在本发明其它实施例中，光电组件15可为发光二极管或液晶显示组件，但不以此为限。
在本发明一实施例中，氢化苯乙烯弹性体树脂层19A可为氢化(苯乙烯-异戊二烯)二嵌段共聚物(poly(styrene-b-isoprene))、氢化(苯乙烯-异戊二烯-苯乙烯)三嵌段共聚物(poly(styrene-b-isoprene-b-styrene))、氢化(苯乙烯-丁二烯-苯乙烯)三嵌段共聚物(poly(styrene-b-butadiene-b-styrene)、氢化(苯乙烯-异戊二烯/丁二烯-苯乙烯)三嵌段共聚物(poly(styrene-b-isoprene/butadiene-b-styrene)、或氢化(苯乙烯-乙烯支化异戊二烯)二嵌段共聚物(apolystyreneblockandavinylbondedrichpolyisopreneblock)。上述共聚物中的聚苯乙烯嵌段，占氢化苯乙烯弹性体树脂层19A的约10wt%至35wt%。在本发明一实施例中，上述共聚物中的聚苯乙烯嵌段，占氢化苯乙烯弹性体树脂层19A的约13wt%至30wt%。若共聚物中的聚苯乙烯嵌段比例过低，则硬度较低及机械拉伸强度变差。若共聚物中的聚苯乙烯嵌段比例过高，则虽然机械强度与硬度皆提升，但是流动性变差不利于加工，且玻璃转移温度(Tg)亦会变高而降低接着性质。上述氢化苯乙烯弹性体树脂层19A的分子量与熔融指数呈负相关，当其熔融指数越高，则分子量越小。若氢化苯乙烯弹性体树脂层19A的熔融指数越低，则分子量越高。在本发明一实施例中，氢化苯乙烯弹性体树脂层19A的熔融指数约介于1.0g/10min至8.0g/10min之间或约介于3.5g/10min至6.5g/10min之间。若氢化苯乙烯弹性体树脂层19A的熔融指数过低，则代表流动性不佳将无法形成均匀膜层。若氢化苯乙烯弹性体树脂层19A的熔融指数过高，流动性太好则容易造成膜层间的混合无法形成各自独立的均匀膜层。
聚烯烃层19B可为聚乙烯、聚丙烯、乙烯-丙烯共聚物、上述之组合、或上述之多层结构。上述聚烯烃层19B的分子量与熔融指数呈负相关，当其熔融指数越高，则分子量越小。若聚烯烃层19B的熔融指数越低，则分子量越高。在本发明一实施例中，聚烯烃层19B的熔融指数约介于1.0g/10min至8.0g/10min之间。若聚烯烃层19B的熔融指数过低，则流动性差将无法形成均匀膜层。若聚烯烃层19B的熔融指数过高，则流动性太好容易造成膜层间的混层作用无法形成各自独立的均匀膜层。
在本发明一实施例中，氢化苯乙烯弹性体树脂层19A的厚度介于50μm至150μm之间。
在本发明一实施例中，聚烯烃层19B的厚度介于200μm至500μm之间。若聚烯烃层19B的厚度过厚，将增加成本与产品重量与厚度。若聚烯烃层19B的厚度过薄，将无法有效保护光电组件15。
在本发明一实施例中，可进一步于背板19的氢化苯乙烯弹性体树脂层19A及/或聚烯烃层19B中添加反射率调控剂、颜料、抗氧化剂、或上述之组合。反射率调控剂可为金属氧化物(例如氧化钛、氧化镁、黏土、或上述之组合)、碳酸钙、氧化硅或上述之组合，可增加模块结构的反射率，可进一步提高太阳能电池(光电组件15)的转换效率。颜料如炭黑、色母粒(pigmentmasterbatch，例如CLARIANTREMAFIN聚烯类色母粒)可改变模块结构的外观颜色，以搭配建筑物的整体风格。至于抗氧化剂如二丁基羟基甲苯(BHT)、双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、二苯酮、上述之衍生物、或上述之组合可进一步避免氢化苯乙烯弹性体树脂层19A及/或聚烯烃层19B产生黄变现象。一般而言，上述添加剂的用量小于氢化苯乙烯弹性体树脂层19A(或聚烯烃层19B)的约10wt%、约0.1wt%至10wt%、或约5wt%至10wt%。过多添加剂会破坏氢化苯乙烯弹性体树脂层19A(或聚烯烃层19B)的加工性质。
在本发明另一实施例中，可进一步增加背板19中氢化苯乙烯弹性体树脂层19A的厚度，以省略封装层17如第2图所示。举例来说，氢化苯乙烯弹性体树脂层19A的厚度可介于150μm至300μm之间。氢化苯乙烯弹性体树脂层19A的厚度增加可提升模块耐冲击性，达到保护光电组件15的目的。由于一般光电组件15的下电极多为不耐酸的材质如铝，而封装层17如EVA在长时间使用后容易因高温或湿气作用释放出醋酸而破坏光电组件15的下电极，进而缩短光电组件15的使用寿命。在省略封装层17的实施例中，光电组件15为直接接触背板19的氢化苯乙烯弹性体树脂层19A，可避免上述问题。
第1图之模块结构的封装层17具有抗冲击能力，因此背板19的聚烯烃层19B不需考虑抗冲击性质而具有较多选择。由于第2图之模块结构省略封装层17，因此背板19的聚烯烃层19B需考虑抗冲击性质。举例来说，第2图之聚烯烃层19B的抗冲击能力需大于约10kg-cm/cm，比如购自台化(台湾化学纤维股份有限公司)之聚丙烯K8002。
为了让本发明之上述和其它目的、特征、和优点能更明显易懂，下文特举数实施例配合所附图示，作详细说明如下：
实施例
实施例1
取100kg氢化苯乙烯弹性体树脂(购自AsahichemicalsCo.Ltd.之LS611，其熔融指数为5.4g/10min)与9kg二氧化钛(购自杜邦之R706)，置入双螺杆混练机中混合造粒。
取100kg聚丙烯(购自台湾化学纤维股份有限公司之K8002，其熔融指数为1.2g/10min)与9kg二氧化钛(购自杜邦之R706)，置入双螺杆混练机中混合造粒。
将混练后的氢化苯乙烯弹性体树脂/二氧化钛粒子，及聚丙烯/二氧化钛粒子分别置于三轴共挤出机之不同进料口中，使挤出成型的氢化苯乙烯弹性体树脂/二氧化钛薄膜贴合于聚丙烯/二氧化钛薄膜上，形成层状结构的背板。此背板的物理性质如第1表所示。
实施例2
与实施例1类似，差别在于聚丙烯由购自台湾化学纤维股份有限公司之K8002改为购自台湾化学纤维股份有限公司之聚丙烯K8009(熔融指数为7.5g/10min)。至于后续层状结构的背板的制作方式与实施例1类似，且背板的物理性质如第1表所示。
实施例3
与实施例1类似，差别在于聚丙烯由购自台湾化学纤维股份有限公司之K8002改为购自台湾塑料工业股份有限公司之永嘉烯2100M(乙烯-丙烯共聚物，熔融指数为7.5g/10min)。至于后续层状结构的背板的制作方式与实施例1类似，且背板的物理性质如第1表所示。
比较例1
直接取市售背板(购自Madico之ProtektHD，protektcoating13μm/PET127μm/adhesive/EVA100μm四层结构)进行物性测试，如第1表所示。
比较例2
直接取市售背板(购自Isovota之IcosolarAAA3554，polyamide/polyamide/polyamide之三层结构)进行物性测试，如第1表所示。
比较例3
直接取市售背板(购自Isovota之IcosolarAPA3552，polyamide/PET/polyamide之三层结构)进行物性测试，如第1表所示。
第1表
检测方法或仪器:
1:HIOKISM-8220，制具:HIOKISME-8311,测试方法:ASTMD257-07
2:Mocon3/60,测试方法:ASTMF1249-06
3:万变试验机-测试方法:ASTM1876-01
4:万变试验机-测试方法:ASTMD-1876-BS-EVA-BS
5:HipotronicModel:730-1,测试方法:ASTMD149
6:扫描式电子显微镜(Scanningelectronmicroscopy,SEM)
由第1表之比较可知，实施例1-3的背板的物性及与EVA的黏着性均优于比较例1-3之市售背板。其中，实施例1-3的破坏电压约达16-18kV、透水率约达0.2-0.4g/m2·天、断裂延伸率约达400-450%、常温下与EVA层黏着力约达60-80N/cm、高温(约90℃)高湿下与EVA层黏着力约达60-80N/cm、经过低温(约6℃)处理后常温下与EVA层黏着力约达60-80N/cm。
实施例4
取100kg氢化苯乙烯弹性体树脂(购自AsahichemicalsCo.Ltd.之LS611，其熔融指数为5.4g/10min)与9kg二氧化钛(购自杜邦之R706)，置入双螺杆混练机中混合造粒。
取100kg聚丙烯(购自台湾化学纤维股份有限公司之K8009，其熔融指数为7.5g/10min)与9kg二氧化钛(购自杜邦之R706)，置入双螺杆混练机中混合造粒。
取100kg聚丙烯(购自台湾塑料工业股份有限公司之YUNGSOX2100，其熔融指数为7.0g/10min)与9kg二氧化钛(购自杜邦之R706)，置入双螺杆混练机中混合造粒。
将混练后的氢化苯乙烯弹性体树脂/二氧化钛粒子，及聚丙烯/二氧化钛粒子分别置于三轴共挤出机之不同进料口中，经由分流器(feedblock)使聚丙烯YUNGSOX2100/二氧化钛薄膜作为中间层，其两侧分别贴合有氢化苯乙烯弹性体树脂/二氧化钛薄膜，以及聚丙烯k8009/二氧化钛薄膜，形成三层状结构的背板(膜层厚度约为0.400mm)，其物理性质如第2表所示。
实施例5
与实施例4类似，差别在于氢化苯乙烯弹性体树脂/二氧化钛薄膜、聚丙烯YUNGSOX2100/二氧化钛薄膜、与聚丙烯k8009/二氧化钛薄膜之薄膜厚度不同于实施例4。实施例5的背板总厚度约为0.500mm，其物理性质如第表2所示。
第2表
检测方法或仪器:
1:HIOKISM-8220，制具:HIOKISME-8311,测试方法:ASTMD257-07
2:Mocon3/60-测试方法:ASTMF1249-06
3:万变试验机-测试方法:ASTM1876-01
4:万变试验机-测试方法:ASTMD-1876-BS-EVA-BS
5:HipotronicModel:730-1-测试方法:ASTMD149
6:扫描式电子显微镜(Scanningelectronmicroscopy,SEM)
7:紫外光可见光光谱仪HitachiU-3010
由第2表之比较可知，实施例1-5的背板的物性及与EVA的粘结性类似。
取实施例1-3的背板(氢化苯乙烯弹性体树脂/二氧化钛层较薄)，依序堆栈厚度为0.42mm的封装膜(EVA型号RC02B，制造商:三井化学MitsuiChemicalsTocelloInc.)、太阳能电池(旺能Delsolar、MonocrystallineD6(6寸)、效率18.4%)、厚度为0.42mm的封装膜(EVA型号RC02B，制造商:三井化学MitsuiChemicalsTocelloInc.)、与厚度为3.2mm的玻璃前板(元璋玻璃公司stanleyglass、18×18cm优白玻璃superclearGlass)，再以层压机(LM-SA-170x260-S)进行150℃、15分钟真空加热封装形成第1图所示之模块结构。上述模块结构进行老化测试(使用UV老化机TMJ-9705WM-UV)照射紫外线(15kWh/m2)及/或90℃水煮不同时间)以确认测试前后的最大功率如第3表所示。上述模块结构亦可直接照射紫外线(15kWh/m2)以确认测试前后的最大功率，如第4表所示。
取实施例4的背板(氢化苯乙烯弹性体树脂/二氧化钛层较厚)，依序堆栈太阳能电池(旺能Delsolar、MonocrystallineD6(6寸)、效率18.4%)、厚度为0.42mm的封装膜(EVA型号RC02B，制造商:三井化学MitsuiChemicalsTocelloInc.)、与厚度为3.2mm的玻璃前板(元璋玻璃公司stanleyglass、18×18cm优白玻璃superclearGlass)，再以层压机(使用LM-SA-170x260-S层压机)进行150℃,15分钟真空加热封装形成第2图所示之模块结构。上述模块结构进行老化测试(使用UV老化机TMJ-9705WM-UV)照射紫外线(15kWh/m2)及90℃水煮不同时间，或仅90℃水煮不同时间，并确认测试前后的最大功率，如第3表所示。上述模块结构亦可直接照射紫外线(15kWh/m2)以确认测试前后的最大功率，如第4表所示。
第3表
第4表
由第3表与第4表之比较可知，第2图之模块结构(省略封装层17)中的太阳能电池，在老化测试后的最大功率损失小于第1图之模块结构中的太阳能电池。上述现象的原因可能为第2图之模块结构中的太阳能电池之下电极(铝)未接触封装层如EVA，因此EVA释放出的醋酸不致劣化太阳能电池的下电极。
Claims (14)
1.一种模块结构，包括：
前板；
背板，与该前板相对设置；
光电组件，设于该前板与该背板之间；以及
第一封装层，设于该光电组件与该前板之间，
其中该背板是氢化苯乙烯弹性体树脂层与聚烯烃层组成的层状结构，且该氢化苯乙烯弹性体树脂层设于该光电组件与该聚烯层之间。
2.如权利要求1所述的模块结构，其中该氢化苯乙烯弹性体树脂层包括氢化苯乙烯-异戊二烯二嵌段共聚物、氢化苯乙烯-异戊二烯-苯乙烯三嵌段共聚物、氢化苯乙烯-丁二烯-苯乙烯三嵌段共聚物、氢化苯乙烯-异戊二烯/丁二烯-苯乙烯三嵌段共聚物或氢化苯乙烯-乙烯支化异戊二烯二嵌段共聚物。
3.如权利要求1所述的模块结构，其中该氢化苯乙烯弹性体树脂层中的聚苯乙烯嵌段，占该氢化苯乙烯弹性体树脂层的10wt％至35wt％。
4.如权利要求1所述的模块结构，其中该氢化苯乙烯弹性体树脂层的熔融指数为1.0g/10min至8.0g/10min。
5.如权利要求1所述的模块结构，其中该第一封装层包括乙烯-醋酸乙烯酯共聚物。
6.如权利要求1所述的模块结构，其中该聚烯烃层包括聚乙烯、聚丙烯、乙烯-丙烯共聚物或上述之组合。
7.如权利要求1所述的模块结构，其中该聚烯烃层为多层结构。
8.如权利要求1所述的模块结构，其中该聚烯烃层的熔融指数为1.0g/10min至8.0g/10min。
9.如权利要求1所述的模块结构，其中该氢化苯乙烯弹性体树脂层的厚度为150μm至300μm。
10.如权利要求1所述的模块结构，其中该聚烯烃层的厚度为200μm至500μm。
11.如权利要求1所述的模块结构，其中该光电组件包括太阳能电池、发光二极管或液晶显示组件。
12.如权利要求1所述的模块结构，更包括第二封装层设于该背板与该光电组件之间。
13.如权利要求12所述的模块结构，其中该第二封装层包括乙烯-醋酸乙烯酯共聚物。
14.如权利要求12所述的模块结构，其中该氢化苯乙烯弹性体树脂层的厚度为50μm至150μm。
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| CN202395001U (zh) * | 2011-12-27 | 2012-08-22 | 青岛泰孚光伏科技有限责任公司 | 新型太阳能电池背板 |
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| EP1117527A4 (en) * | 1998-09-04 | 2003-05-14 | Avery Dennison Corp | COEXTRUDED STICKERS |
| US20060166023A1 (en) * | 2002-09-06 | 2006-07-27 | Dai Nippon Printing Co., Ltd. | Backside protective sheet for solar battery module and solar battery module using the same |
| JP5385640B2 (ja) * | 2009-03-10 | 2014-01-08 | テクノポリマー株式会社 | 積層シート及びそれを備える太陽電池モジュール |
| EP2460266A4 (en) * | 2009-07-31 | 2013-07-17 | Du Pont | NETWORKABLE PACKAGING MATERIALS FOR PHOTOVOLTAIC CELLS |
| JP5612970B2 (ja) * | 2010-09-03 | 2014-10-22 | 電気化学工業株式会社 | 太陽電池モジュール用裏面保護シート |
| JP2012079849A (ja) * | 2010-09-30 | 2012-04-19 | Sumitomo Bakelite Co Ltd | 太陽電池封止材用フィルム |
| CN102569452B (zh) * | 2010-10-20 | 2014-10-15 | 苏州尚善新材料科技有限公司 | 太阳能电池组件聚合物背板及其制造方法 |
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| JP2012107107A (ja) * | 2010-11-17 | 2012-06-07 | Aron Kasei Co Ltd | 太陽電池封止用フィルムの組成物 |
| US20120318354A1 (en) * | 2010-12-29 | 2012-12-20 | E. I. Du Pont De Nemours And Company | Photovoltaic module with chlorosulfonated polyolefin layer |
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- 2013-08-13 CN CN201310350531.9A patent/CN103840023B/zh active Active
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101317276A (zh) * | 2005-11-29 | 2008-12-03 | 大日本印刷株式会社 | 太阳电池组件用背面保护片、太阳电池组件用背面层叠体以及太阳电池组件 |
| TW201129621A (en) * | 2009-12-04 | 2011-09-01 | Jsr Corp | Sealing material, laminated sheet for solar cell module, and solar cell module |
| CN202395001U (zh) * | 2011-12-27 | 2012-08-22 | 青岛泰孚光伏科技有限责任公司 | 新型太阳能电池背板 |
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| CN103840023A (zh) | 2014-06-04 |
| EP2732970A1 (en) | 2014-05-21 |
| TWI497734B (zh) | 2015-08-21 |
| TW201421713A (zh) | 2014-06-01 |
| JP2014103399A (ja) | 2014-06-05 |
| JP5715221B2 (ja) | 2015-05-07 |
| EP2732970B1 (en) | 2015-06-24 |
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