CN103928548B - 太阳能电池模块及成型方法 - Google Patents
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- 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
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
-
- 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
-
- 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
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Condensed Matter Physics & Semiconductors (AREA)
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- Computer Hardware Design (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
本发明涉及一种既具有优异的耐候性能,又具有可靠的密封性能的太阳能电池模块及成型方法,包括太阳能芯片,所述太阳能芯片四周被改性PVC糊料密封包覆。太阳能电池模块成形材料采用改性PVC糊料。优点:一是采用PVC糊作为太阳能芯片模芯密封的成形材料,不仅具有良好的耐紫外线、耐低温、耐候性,而且阻燃达到V‑1至V‑0级;二是可以根据用户的不同需求用太阳能电池模块成形所需太阳能板的外形,不仅从根本上改变了本领域技术人员常期以来认为改性PVC糊料不能作为太阳能电池密封成形材料的技术偏见,而且从根本上改变了太阳能芯片只能矩形分布而不能随造形分布的技术偏见。
Description
技术领域
本发明涉及一种既具有优异的耐候性能,又具有可靠的密封性能的太阳能电池模块及成型方法,属太阳能电池密封材料制造领域。
背景技术
1、CN103189996A、名称“太阳能电池密封材料”,其包含满足以下要件a1)~a4)的乙烯-α-烯烃共聚物,a1)来源于乙烯的构成单元的含有比例为80~90mol%,并且来源于碳原子数3~20的α-烯烃的构成单元的含有比例为10~20mol%,a2)按照ASTM D1238,在190℃、2.16kg荷重的条件下测定得到的MFR为2g/10分钟以上且低于10g/10分钟,a3)按照ASTM D1505测定得到的密度为0.865~0.884g/cm3,a4)按照ASTM D2240测定得到的肖氏A硬度为60~85。
2、CN101375409A、名称“太阳能电池密封材料”,含有交联性树脂组合物(A),所 述交联性树脂组合物(A)以乙烯·(甲基)丙烯酸酯共聚物为原料聚合物,含有所述原料聚合物和有机过氧化物及交联助剂,其特征在于,所述有机过氧化物的分解温度(1小时半衰期温度)为150℃以下,有机过氧化物和交联助剂的总配合量相对于每100重量份原料聚合物在0.5~5重量份的范围内,有机过氧化物和交联助剂的配比即有机过 氧化物/交联助剂按重量比计在1/5~1/0.1的范围内。
3、CN 101138095A、名称“太阳能电池密封材料”,由粘接耐热层(A)和缓冲层(B)层叠而成,粘接·耐热层(A)和缓冲层(B)的弯曲刚性模量的差值至少在30MPa 以上。
4、CN 101872795A、名称“太阳模块封装结构”,包括:背板;玻璃面板。位于该背板上方;太阳电池,位于该背板与该玻璃面板之间;粘胶物质,位于该背板与该玻璃面板之间,固定并包覆住该太阳电池;以及第一光学板,位于该太阳电池上方,其中该第一光学板设置于该玻璃面板与该太阳电池之间而位于该粘胶物质之中,而该第一光学板远离该太阳电池的受光表面为正向并具有凹凸结构,而该第一光学板朝向该太阳电池的表面为背向,而该第一光学板具正向高穿透与背向高反射。
发明内容
设计目的:设计一种既具有优异的耐候性能和可靠的密封性能,又能够独立地作为太阳能电池密封材料,同时又能使成形的太阳能电池模块长期在户外工作且水汽渗入的太阳能电池模块及成型方法。
设计方案:为了实现上述设计目的。本发明采用改性PVC糊料作为太阳能模块密封材料的设计,是本发明的主要技术特征。这样设计的目的在于:它改变长期以来本领域技术人员认为的PVC糊由于分散性能良好,只能用于软材料领域使用,如人造革、搪胶玩具、软质商标、墙纸、油漆涂料、发泡塑胶等,不能作为太阳能电池密封成形材料的技术偏见。本申请反其道之,采用PVC糊作为太阳能电池密封成形材料,不仅可以使太阳能板根据用户需要成形为各种形状,而且所成形的太阳能电池易于浇注、透光效果好、耐热、抗冲击、抗撕裂,并且可以实现少量、多品种化生产,更重要的是该材料实现了太阳能电池密封长期在户外的全密封、全天候的耐候使用。
本申请在PVC糊中添加用于吸收紫外线的吸收剂,因为紫外线吸收剂能吸收阳光或荧光源中紫外线部分,而本身结构不起变化,它能将高能量的紫外线光能转换成热能或无破坏性的较长光波释放出来,从而保护添加有紫外线吸收剂的物质免遭紫外线破坏,在PVC糊中添加紫外线吸收剂能有效阻止阳光中的紫外线对太阳能电池密封模块的破坏,延长太阳能电池模块的使用寿命。
本申请在PVC糊中添加抗氧剂的目的在于:由于塑化后的PVC糊塑料在光、热、氧、溶剂、助剂、HCl等因素作用下易老化,即降解或交联,使其物理机械性能变坏,缩短使用寿命。本申请PVC糊中加入抗氧剂有效地抑制或降低塑料大分子的热氧化、光氧化反应速度,显著地提高塑化后的PVC糊塑料的耐热、耐光性能,延缓塑化后的PVC糊塑料的降解、老化过程,改善PVC糊所制太阳能电池模块的耐侯性,延长塑化后的PVC糊塑料制品使用寿命。
本申请在PVC糊中添加低温增塑剂的目的在于:由于低温增塑剂与PVC糊树脂具有良好的相容性,增塑效果好,不易离析、不易渗出,并且低温增塑剂可降低塑化后的PVC糊塑料的玻璃化温度,使其柔韧性好,能够改善塑化后的PVC糊塑料的耐寒性能,使其在寒冷地区仍有较好的使用性能。
本申请在PVC糊中添加稳定剂的目的在于:改性PVC糊料在高温下塑化或高温下使用,极易放出HCL,形成不稳定的聚烯结构。同时,HCL具有自催化作用,会使PVC进一步降解。另外,假如有氧存在或有铁、铝、锌、锡、铜和镉等离子存在,都会对PVC降解起催化作用,加速其老化。因此塑料将出现各种不良现象,如变色、变形、龟裂、机械强度下降、缘性能下降、发脆等。为了解决这些问题,PVC糊塑料中必须加进不同品种,不同数目的稳定剂。
技术方案1:一种太阳能电池模块,包括太阳能芯片,所述太阳能芯片四周被改性PVC糊料密封包覆。
技术方案2:一种太阳能电池模块成型方法,根据用户所需太阳能芯片的大小制作太阳能电池模块成型模,将太阳能芯片1悬空在太阳能电池模块成型模的型腔中,然后将改性PVC糊料注入到太阳能电池模块成型模的型腔中,加温15-30分钟,使太阳能电池模块成型模腔中的改性PVC糊料固化后,将固化后的太阳能电池模块从太阳能电池模块成型模的型腔中脱出,即得太阳能电池模块。
本发明与背景技术相比,一是采用PVC糊作为太阳能芯片模芯密封的成形材料,不仅具有良好的耐紫外线、耐低温、耐候性,而且阻燃达到V-2至V-0级;二是可以根据用户的不同需求用太阳能电池模块成形所需太阳能板的外形,不仅从根本上改变了本领域技术人员常期以来认为改性PVC糊料不能作为太阳能电池密封成形材料的技术偏见,而且从根本上改变了太阳能芯片只能矩形分布而不能随造形分布的技术偏见。
附图说明
图1是太阳能模块的剖视结构示意图。
具体实施方式
实施例1:参照附图1。一种太阳能电池模块,包括太阳能芯片1,所述太阳能芯片1四周被改性PVC糊料2密封包覆。所述太阳能芯片1电源线密封穿过改性PVC糊料层。本申请所说的改性PVC糊料是指含有增塑剂的改性PVC糊料。
实施例2:在实施例1的基础上,所述太阳能芯片1为单片封装,即单片太阳能电池(模块)。
实施例3:在实施例1的基础上,所述太阳能芯片1为多片封装,即多片太阳能芯片1被PVC糊料2密封包覆构成太阳能电池模块,多片太阳能芯片1之间的串并联系现有技术,在此不作叙述。
实施例4:在实施例1的基础上,所述PVC糊中含有紫外线吸收剂,紫外线吸收剂添加量为100份PVC糊树脂添加0.1份至0.8份紫外线吸收剂。所述紫外线吸收剂为紫外线吸收剂UV-531、紫外线吸收剂UV-327、紫外线吸收剂UV-326、紫外线吸收剂UV-74、紫外线吸收剂UV-9、紫外线吸收剂UV-P一种或一种以上的组合。
实施例5:在实施例1的基础上,所述PVC糊中含有抗氧剂。抗氧剂添加量为100份PVC糊树脂添加每种0.5份至1份抗氧剂。所述抗氧化剂为抗氧剂2246、抗氧剂1520、抗氧剂1098、抗氧剂1076、抗氧剂1010、抗氧剂300、抗氧剂264、抗氧剂168一种或一种以上组合。
实施例6:在实施例1的基础上,所述PVC糊中含有耐低温添加剂。耐低温添加剂添加量为100份PVC糊树脂添加5份至20份低温增塑剂。所述耐低温添加剂为已二酸二异癸酯(简称DIDA)、己二酸二辛酯(简称DOA)、壬二酸二辛酯(简称DOZ)、癸二酸二丁酸(简称DBS)、癸二酸二辛酯(简称DOS)、癸二酸二异辛酯(简称DIOS)一种或一种以上组合。
实施例7:在实施例1的基础上,所述PVC糊中含有稳定剂。稳定剂添加量为100份PVC糊树脂添加每种0.5份至5份稳定剂。所述稳定剂为辛基硫醇锡、辛基氧化锡、二月桂酸二正辛基锡、马来酸二正辛基锡、丁基硫醇锡、马来酸二丁基锡、月桂酸马来酸二丁基锡、月桂酸马来酸二丁基锡、双丁基氧化锡、二甲基氧化锡、环氧大豆油、环氧胡麻油、亚磷酸脂。
实施例8:在实施例1的基础上,所述PVC糊中含阻燃增塑剂。阻燃增塑剂添加量为100份PVC糊树脂添加5份至15份阻燃增塑剂。所述阻燃增塑剂为DP-45、磷酸三甲苯酯(TCP)、磷酸三苯酯(TPP)、磷酸三丁酯(TBP)、磷酸三辛酯(TOP)、磷酸二苯一辛酯(DPOP)一种或一种以上组合。
实施例9:在上述实施例的基础上,一种太阳能电池模块成形方法,根据用户所需太阳能芯片1的大小制作太阳能电池模块成型模,将太阳能芯片1悬空在太阳能电池模块成型模的型腔中,然后将改性PVC糊料注入到太阳能电池模块成型模的型腔中,加温15-30分钟,使太阳能电池模块成型模腔中的改性PVC糊料固化后,将固化后的太阳能电池模块从太阳能电池模块成型模的型腔中脱出,即得太阳能电池模块。所述加温为烘箱加温或烘道加温。
需要理解到的是:上述实施例虽然对本发明的设计思路作了比较详细的文字描述,但是这些文字描述,只是对本发明设计思路的简单文字描述,而不是对本发明设计思路的限制,任何不超出本发明设计思路的组合、增加或修改,均落入本发明的保护范围内。
Claims (14)
1.一种太阳能电池模块,包括太阳能芯片(1),其特征是:所述太阳能芯片(1)四周被改性PVC糊料(2)密封包覆;其成型方法:根据用户所需太阳能芯片的大小制作太阳能电池模块成型模,将太阳能芯片悬空在太阳能电池模块成型模的型腔中,然后将改性PVC糊料注入到太阳能电池模块成型模的型腔中,加温15-30分钟,使太阳能电池模块成型模腔中的改性PVC糊料固化后,将固化后的太阳能电池模块从太阳能电池模块成型模的型腔中脱出且太阳能芯片电源线密封穿过改性PVC糊料层,即得太阳能电池模块,阻燃达到V-2至V-0级。
2.根据权利要求1所述的太阳能电池模块,其特征是:所述太阳能芯片(1)为单片封装。
3.根据权利要求1所述的太阳能电池模块,其特征是:所述太阳能芯片(1)为多片封装。
4.根据权利要求1所述的太阳能电池模块,其特征是:所述改性PVC糊料中含有紫外线吸收剂。
5.根据权利要求4所述的太阳能电池模块,其特征是:所述紫外线吸收剂为紫外线吸收剂UV-531、紫外线吸收剂UV-327、紫外线吸收剂UV-326、紫外线吸收剂UV-74、紫外线吸收剂UV-9、紫外线吸收剂UV-P。
6.根据权利要求1所述的太阳能电池模块,其特征是:所述改性PVC糊料中含有抗氧剂。
7.根据权利要求6所述的太阳能电池模块,其特征是:所述抗氧化剂为抗氧剂2246、抗氧剂1520、抗氧剂1098、抗氧剂1076、抗氧剂1010、抗氧剂300、抗氧剂264、抗氧剂168。
8.根据权利要求1所述的太阳能电池模块,其特征是:所述改性PVC糊料中含有耐低温添加剂。
9.根据权利要求8所述的太阳能电池模块,其特征是:所述耐低温添加剂为已二酸二异癸酯(简称DIDA)、己二酸二辛酯(简称DOA)、壬二酸二辛酯(简称DOZ)、癸二酸二丁酸(简称DBS)、癸二酸二辛酯(简称DOS)、癸二酸二异辛酯(简称DIOS)。
10.根据权利要求1所述的太阳能电池模块,其特征是:所述改性PVC糊料中含有稳定剂。
11.根据权利要求10所述的太阳能电池模块,其特征是:所述稳定剂为辛基硫醇锡、辛基氧化锡、二月桂酸二正辛基锡、马来酸二正辛基锡、丁基硫醇锡、马来酸二丁基锡、月桂酸马来酸二丁基锡、月桂酸马来酸二丁基锡、双丁基氧化锡、二甲基氧化锡、环氧大豆油、环氧胡麻油、亚磷酸脂。
12.根据权利要求1所述的太阳能电池模块,其特征是:所述改性PVC糊料中含阻燃增塑剂。
13.根据权利要求12所述的太阳能电池模块,其特征是:所述阻燃增塑剂为DP-45、磷酸三甲苯酯(TCP)、磷酸三苯酯(TPP)、磷酸三丁酯(TBP)、磷酸三辛酯(TOP)、磷酸二苯一辛酯(DPOP)。
14.根据权利要求1所述的太阳能电池模块,其特征是:所述加温为烘箱加温或烘道加温。
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