CN104968755A - 用于pv模块热管理的相变材料的新型共聚物 - Google Patents

用于pv模块热管理的相变材料的新型共聚物 Download PDF

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CN104968755A
CN104968755A CN201380063950.2A CN201380063950A CN104968755A CN 104968755 A CN104968755 A CN 104968755A CN 201380063950 A CN201380063950 A CN 201380063950A CN 104968755 A CN104968755 A CN 104968755A
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J·韩
W·J·王
H·张
N·黄
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Honeywell International Inc
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Abstract

本发明涉及可与光伏(PV)模块一起使用的相变材料(PCM)。更具体地，提供了具有聚烯烃骨架聚合物和可结晶侧链的固/固PCM。优选地，该固/固PCM具有含有聚烯烃重复单元的共聚物骨架，并且可结晶侧链被接枝到共聚物骨架上。更优选地，该共聚物为聚(乙烯-共-甲基丙烯酸缩水甘油酯)(PE-co-GMA)，并且聚乙二醇(PEG)是可结晶侧链。还提供了光伏模块和用于具有固/固PCM的光伏模块的背板。

Description

用于PV模块热管理的相变材料的新型共聚物
相关申请的交叉引用
本申请要求于2012年12月10日提交的美国临时专利申请No.61/735,413的权益，其公开内容在此通过引用以其整体并入本文。
技术领域
本发明涉及可与光伏(PV)模块一起使用的相变材料(PCM)。
背景技术
目前，含氟聚合物和聚(对苯二甲酸乙二醇酯)(PET)的复合物通常用于光伏模块的背板中。例如，在外侧的含氟聚合物层提供耐候性，并且在芯层中的PET提供介电绝缘和机械强度。另外，芯层另一面上的另一含氟聚合物层可以提供与光伏模块中的封装材料(encapsulant material)，例如乙烯丙烯酸乙烯酯(EVA)封装料的粘结。
但是，使用含氟聚合物和PET的背板具有若干缺点。其一，PET是易水解的，且因此可能在高温和/或潮湿条件下失效。其二，含氟聚合物(如PVF、PVDF或ETFE)难以加工成膜，其价格昂贵，并且受制于原料的供应。其三，不同聚合物层的使用要求用粘合剂将它们粘结在一起，并且该粘合剂可能在长时间的户外使用中失效。
因此，已经研究了大量的可与光伏模块一起使用的可替换的背板组合物。例如，Honeywell公司已经开发了复配的热塑性聚烯烃层，其与EVA封装的光伏模块粘合良好，然而，相较于现有技术，其具有在高操作温度下的有利性能且不具有高水蒸气渗透率。此类层的实例可见于在2012年11月29日提交的，题为“Photovoltaic Module Backsheet Having a Thermoplastic Polyolefin CompositeLayer”(“具有热塑性聚烯烃复合层的光伏模块背板”)的美国临时申请61/731,400(“400申请”)，其在此通过引用并入本文。
然而，光伏模块中的高温不仅会影响其中材料的完整性，高温还可以影响光伏模块的电力生产。研究已经确认，硅光伏电池的电力产出随着温度增加急剧下降。例如，如美国专利申请公开No.2010/0288333 A1(“333申请”)中指出的那样，与25℃的测试温度相比，在64℃的温度下晶体硅光伏模块的效率预期减少69％。“333申请”提出在光伏模块背板中使用固/液PCM；但是与在“400申请”中解决的问题类似，当PCM呈液态时，这类材料在高温下具有不良的尺寸稳定性。
发明概述
为了解决上述问题，本发明人研究了与光伏模块一起使用的固/固相变材料(固/固PCM)。固/固PCM是一种当其用于光伏模块中时，能够通过由晶体形式转变为无定形形式来清除和储存多余热量的材料。固/固PCM可用于或并入各种对有温度调节和蓄热有需求的产品和应用中。例如，按照本发明的固/固PCM可以加工成膜和并入到光伏模块中。
根据本发明的第一方面，提供一种具有聚烯烃骨架聚合物和可结晶侧链的复配型固/固PCM。更具体地，该固/固PCM具有带有聚烯烃重复单元的共聚物骨架，并且可结晶侧链接枝至共聚物骨架上。最具体地，该共聚物为聚(乙烯-共-甲基丙烯酸缩水甘油酯)(PE-co-GMA)，并且聚乙二醇(PEG)是可结晶侧链。
根据本发明的第二方面，按照本发明的固/固PCM在约25℃至约75℃的温度下经历相变。甚至更优选地，按照本发明的固/固PCM在约35℃至约70℃的温度下经历相变。最优选地，按照本发明的固/固PCM在约35℃至约60℃的温度下经历相变。
根据本发明的第三方面，按照本发明的固/固PCM具有至少40kJ/kg的相变潜热。甚至更优选地，按照本发明的固/固PCM具有至少50kJ/kg的相变潜热。
根据本发明的第四方面，提供一种制备PCM的方法，其包括将可结晶侧链接枝至含有聚烯烃的共聚物的非烯烃单元上。优选地，该可结晶侧链是PEG，并且甲基丙烯酸缩水甘油酯是非烯烃单元。
根据本发明的第五方面，提供一种包含固/固PCM的背板，该固/固PCM在约25℃至约75℃的温度下经历相变。甚至更优选地，所述背板中的固/固PCM在约35℃至约70℃的温度下经历相变。最优选地，所述背板中的固/固PCM在约35℃至约60℃的温度下经历相变。
根据本发明的第六方面，提供一种包含固/固PCM的光伏模块，该固/固PCM在约25℃至约75℃的温度下经历相变。甚至更优选地，所述背板中的固/固PCM在约35℃至约70℃的温度下经历相变。最优选地，所述背板中的固/固PCM在约35℃至约60℃的温度下经历相变。
附图说明
已选择具体的实施例用于说明和描述，并且这些实施例显示在附图中，形成说明书的一部分。
图1A和1B，分别图解了本发明的固/固PCM的IR和H NMR波谱分析。
图2A和2B图解了本发明的固/固PCM的差示扫描量热(DSC)分析。
图3图解了本发明的一个三层复合背板的实施例。
图4图解了可用于本发明的光伏模块中的第二固/固PCM的差示扫描量热(DSC)分析。
详细说明
已合成的固/固PCM共聚物的一个实施例包含具有聚烯烃重复单元和PEG侧链的骨架。骨架聚合物为聚(乙烯-共-甲基丙烯酸缩水甘油酯)(PE-co-GMA)。反应性基团是GMA单元的环氧基团。可结晶侧链是含有羟基基团的PEG。通过环氧基团与羟基基团之间的反应，将PEG单元接枝到骨架聚合物上，随后获得PCM共聚物聚(乙烯-共-甲基丙烯酸缩水甘油酯-接枝-乙二醇)(PE-co-GMA-g-PEG)。反应图示如下所示：
其中x为聚乙烯单元中重复基团的数量，y为甲基丙烯酸缩水甘油酯单元的重复基团的数量，且n为PEG单元中重复基团的数量。
共聚物PE-co-GMA-g-PEG的合成方法如下：将350g的PEG(MW＝4000)加入到装有搅拌器、冷凝器、氮气吹扫和温度控制器的烧瓶中，随后加热至80℃。将30g的PE-co-GMA溶于1.5L甲苯中。将PE-co-GMA的溶液逐滴加入到烧瓶中并使温度在80℃保持6小时。在溶液冷却后，将共聚物的溶液与过量的PEG分离。蒸发掉大部分溶剂，在120℃下干燥5小时后获得共聚物树脂。
使用IR和H NMR波谱法以及差示扫描量热仪(DSC)对该固/固PCM进行测试。
如从图1中的NMR波谱中可以看出，在固/固PCM共聚物中出现了归属于PEG的峰(d，3.6～3.7)。尽管在该化学位移中存在归属于骨架聚合物的峰，这个峰强度的明显增加证明了在PCM共聚物中存在PEG。从IR测试可以看出，在PCM共聚物的光谱中出现了归属于PEG的在3500cm-1(羟基)和1100cm-1(醚基)的新的峰。这些测试结果都证明了PEG成功地接枝到骨架聚合物上。
已测试了PCM共聚物的热性能。从图2A和图2B中所示的DSC热曲线可以看出，相变温度覆盖了40～70℃，并且相变潜热为约50kJ/kg。此外，潜热共聚物在十次循环下是稳定的。
根据固/固PCM在室温和相变温度以上的升高温度下的视觉比较，固/固PCM共聚物的膜保持呈固态。因此，这表明PCM共聚物发生固/固相变。
因此，按照本发明的固/固PCM可并入光伏模块的背板中，或另外与光伏模块一起使用，而不会经历现有技术所经历的尺寸稳定性问题。例如，背板可以具有任意合适数量的层，包括例如，图3中所示的三层结构。如图1所示，背板100包括第一外层101、内层102、以及第二外层103。背板100可以使用任意合适的设备，包括例如层压机或挤出机来制得。层可以基于特定应用的需要来确定尺寸。更优选地，本发明的固/固PCM与其它层共挤出以形成背板。甚至更优选地，并且更有利地，本发明的固/固PCM中的聚烯烃单元确保与背板中其它聚烯烃的相容性。最优选地，将至少一些固/固PCM并入背板的外层中，或另外与光伏模块的发电部分的封装料直接接触，以容易地来从发电部分清除和移除热量。
优选地，聚烯烃和它们的带有反应性基团的共聚物在本发明中作为骨架聚合物使用。所述聚烯烃包括聚乙烯(PE)、聚丙烯(PP)、聚-1-丁烯、聚-4-甲基-1-戊烯、乙烯-丙烯共聚物、乙烯-丙烯-二烯三元共聚物和它们的混合物。反应性基团的实例包括环氧化物、缩水甘油基、羧酸、酸酐、羟基等。
优选地，按照本发明所使用的可结晶侧链是在模块中具有至少一种反应性基团的化合物。反应性基团的实例包括羟基、羧酸、胺、酰氯等。可结晶侧链的实例包括：具有端羟基的聚醚(例如，重均分子量(MW)为1,000至100,000的聚(乙二醇)(PEG)、MW为100,000至1,000,000的聚(环氧乙烷)(PEO)、聚(丙二醇)、聚(四氢呋喃醚二醇)等)，脂肪醇(例如，月桂醇(C12H26O)；肉豆蔻醇(C14H29OH)；鲸蜡醇(C16H33OH)；硬脂醇(C18H37OH)；花生醇(C20H41OH)等)；脂肪酸(月桂酸(C11H23COOH)、肉豆蔻酸(C13H27COOH)、棕榈酸(C15H31COOH)、硬脂酸(C17H35COOH)等)；以及脂肪胺(例如，十四烷基胺(C14H29NH2)、十六烷基胺(C16H33NH2)、十八烷基胺(C18H37NH2)等)。
优选地，对骨架聚合物和可结晶侧链进行选择以使按照本发明的固/固PCM在约25℃至约75℃的温度下经历相变。甚至更优选地，按照本发明的固/固PCM在约35℃至约70℃的温度下经历相变。最优选地，按照本发明的固/固PCM在约35℃至约60℃的温度下经历相变。
按照本发明的优选的固/固PCM具有至少40kJ/kg的相变潜热。甚至更优选地，按照本发明的固/固PCM具有至少50kJ/kg的相变潜热。
如前所述，用于本发明的光伏模块中的一种优选的固/固PCM包含具有聚烯烃重复单元(即，聚乙烯)和可结晶侧链(例如，PEG)的共聚骨架。可选地，按照本发明，具有非共聚的聚烯烃骨架(例如聚丙烯)的固/固PCM可用于光伏模块中，条件是固/固PCM在约25℃至约75℃的温度下经历相变。这样的基于氯化聚丙烯和PEG的接枝共聚物如下制备：
在装有机械搅拌器、冷凝器并通入氮气的烧瓶中将6g的氯化聚丙烯(CPP)和200g的PEG(MW＝4000)溶于甲苯(200ml)中。将NaOH(4.4g)作为催化剂加入到烧瓶中。溶液在120℃下搅拌约4-5小时。然后在溶液冷却至室温后，将该溶液倒入1L甲醇中。将沉淀物从混合溶液中过滤，并随后相继用甲醇和水洗涤。在真空烘箱中干燥后得到淡黄色粉末。
如图4中描绘的DSC测试所示，该接枝共聚物在约40-50℃具有固-固相变，且相变潜热为大约60-80kJ/kg。
从上文中将要理解的是虽然出于说明的目的已在本文中描述了具体的实施例，但是可以在不背离本公开内容的精神和范围的情况下做出各种改变。因此意在将上文的详细描述仅视为说明性的而非限制性的，并且要理解的是下面的权利要求书，包括所有的等价物意在特别地指出和明确地主张所要求保护的主题。

Claims (10)

1.一种固/固相变材料，其包含：
具有聚烯烃重复单元的骨架共聚物；和，
接枝到所述骨架聚合物上的可结晶侧链，
其中所述固/固相变材料在约30℃至约75℃的温度下经历相变。
2.权利要求1的固/固相变材料，其中所述骨架共聚物具有两种类型的重复单元，其中所述重复单元之一不是聚烯烃。
3.权利要求2的固/固相变材料，其中所述聚烯烃重复单元选自聚乙烯(PE)、聚丙烯(PP)、聚-1-丁烯、聚-4-甲基-1-戊烯、乙烯-丙烯共聚物、乙烯-丙烯-二烯三元共聚物和它们的混合物。
4.权利要求3的固/固相变材料，其中至少一种重复单元具有选自环氧化物、缩水甘油基、羧酸、酸酐、羟基和它们的混合物的反应性基团。
5.权利要求1的固/固相变材料，其中所述可结晶侧链选自具有端羟基的聚醚、脂肪醇、脂肪酸、脂肪胺和它们的混合物。
6.权利要求1的固/固相变材料，其中所述共聚物是聚(乙烯-共-甲基丙烯酸缩水甘油酯)(PE-co-GMA)，并且聚乙二醇(PEG)是可结晶侧链。
7.权利要求1的固/固相变材料，其中所述固/固相变材料在约40℃至约70℃的温度下经历相变。
8.权利要求1的固/固相变材料，其中所述固/固相变材料具有至少40kJ/kg的相变潜热。
9.用于光伏模块的背板，其包含权利要求1的固/固相变材料。
10.包含固/固相变材料的光伏模块，其中所述固/固相变材料在约30℃至约75℃的温度下经历相变。
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