CN107895747A - 一种紫外交联型太阳能电池背板 - Google Patents
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Abstract
本发明涉及一种紫外交联型太阳能电池背板及其制备方法。所述太阳能电池背板由基材层和涂布于基材两面的氟聚合物耐候层组成,所述氟聚合物耐候层包含以下重量份的组分:含氟树脂,20‑40份;聚合物树脂填料,5‑10份;光敏性小分子,8‑15份;无机填料,2‑5份;溶剂,50‑70份。本发明提供的紫外交联型太阳能电池背板,在紫外光照射下,含有光敏性基团的氟聚合物耐候层与表面处理过的基材PET之间通过[2+2]环加成反应快速形成稳定的环丁烷交联结构,使氟聚合物耐候层与基材PET之间的通过化学键连接,粘结能力强且稳定,可以有效的解决耐候氟聚合物层从背板脱落的问题,保证了太阳能电池的使用寿命。
Description
技术领域
本发明涉及太阳能电池背板技术领域,具体涉及一种紫外交联型太阳能电池背板及其制备方法。
背景技术
太阳能电池背板位于太阳能电池板的背面,对电池片起保护和支撑作用,对光伏组件使用寿命有重要影响。近年来随着光伏行业的兴起,背板行业也成为人们关注的焦点。太阳能电池背板目前比较常用的结构有TPT结构和TPE结构,其中T指杜邦公司的Tedlar薄膜,成分为聚氟乙烯(PVF)薄膜,P指聚对苯二甲酸乙二醇酯(PET)薄膜,E指乙烯-醋酸乙烯树脂(EVA)薄膜,三层薄膜间通过粘结剂粘结。TPT结构即PVF薄膜/PET薄膜/PVF薄膜结构,TPE结构即PVF薄膜/PET薄膜/EVA薄膜结构。但是,PVF加工困难且薄膜成型工艺复杂,部分背板产品开始用其它氟塑料如聚偏氟乙烯(PVDF)、乙烯-三氟氯乙烯共聚物(ECTFE)、四氟乙烯-六氟丙烯-偏氟乙烯(THV)等来代替PVF薄膜。
上述氟塑料虽然具有很好的耐候性,但是表面能比较低,存在粘结剂在氟塑料表面不容易展开、其本身也不容易和其它的塑料粘合的问题。因此,现有技术一般在氟塑料和基材层之间设置粘结层,如专利CN 102922843A通过在基材上预先涂上粘结层(EVA,环氧胶,丙烯酸胶等),然后再将氟聚合物薄膜与基材复合;再如专利CN 106218157A公开了一种含高粘结层的太阳能电池背板,其高粘结层由马来酸酐与甲基丙酸羟乙酯的共聚物组成。但是,这种物理粘附的方式长期暴露在户外,氟聚合物膜同样不可避免地会发生脱落,导致光伏组件失效,且额外增加粘结层,必然导致背板成本的上升。
因此,需要找到一种更为有效的、稳定性高的化学键粘结方式,以解决背板在使用过程中出现的氟聚合物耐候层脱落而导致光伏组件失效的问题。
发明内容
本发明的目的是针对目前太阳能电池背板中氟聚合物耐候层与基材之间粘结性差、易发生脱落而导致光伏组件失效的问题,提供一种稳定性高、粘结力牢固的背板及其制备方法。
为达到上述目的,本发明采用的技术方案如下:
一方面,本发明提供一种紫外交联型太阳能电池背板,其由基材层和涂布于基材两面的氟聚合物耐候层组成,所述氟聚合物耐候层包含以下重量份的组分:含氟树脂,20-40份;聚合物树脂填料,5-10份;光敏性小分子,8-15份;无机填料,2-5份;溶剂,50-70份。
进一步的,所述氟聚合物耐候层的厚度为20-50μm。
进一步的,所述基材为聚对苯二甲酸乙二酯(PET),厚度为100-200μm。
进一步的,所述含氟树脂为聚四氟乙烯(PTFE)、聚偏氟乙烯(PVDF)、乙烯-三氟氯乙烯共聚物(ECTFE)、偏氟乙烯-四氟乙烯共聚物中的一种或至少两种的混合物。
在一些实施方式中,所述含氟树脂为聚四氟乙烯(PTFE)、聚偏氟乙烯(PVDF)、乙烯-三氟氯乙烯共聚物中的任一种。
进一步的,所述聚合物树脂填料为侧链含有羟基的聚合物树脂,羟基可与光敏剂发生反应,增加耐候层与基材之间的粘结力。
在一些实施方式中,所述侧链含有羟基的聚合物树脂为聚乙烯醇、聚甲基丙烯酸羟乙酯、聚甲基丙烯酸羟丙酯中的一种或至少两种的混合物。但并不限于上述列举的聚合物树脂,其他本领域常用的可达到相同效果的聚合物树脂也可用于本发明。
进一步的,本发明中选用光敏性小分子代替传统的光引发剂,在紫外光照射下,所述光敏性小分子中的光敏基团通过[2+2]环加成反应,快速形成稳定的环丁烷交联结构,使氟聚合物耐候层和基材PET之间通过化学键连接,粘结能力强且稳定,可以有效的解决氟聚合物耐候层从背板中脱落的问题,保证太阳能电池背板在户外恶劣环境下长期使用。
在一些实施方式中,所述光敏性小分子为肉桂酰氯、香豆素-6-磺酰氯、1-(甲基酰氯)胸腺嘧啶及其衍生物中的一种或至少两种的混合物。所述1-(甲基酰氯)胸腺嘧啶衍生物典型但非限制性实例有:1-(乙基酰氯)胸腺嘧啶,1-(丙基酰氯)胸腺嘧啶,等等。
其中,肉桂酰氯、香豆素-6-磺酰氯、1-(甲基酰氯)胸腺嘧啶结构如下所示:
进一步的,所述无机填料为二氧化钛、二氧化硅、碳酸钙中一种或至少两种的混合物。
进一步的,所述溶剂为醋酸乙酯、丁酮、甲苯、醋酸丁酯中一种或至少两种的混合物。
另一方面,本发明还提供上述紫外交联型太阳能电池背板的制备方法,包括:
(1)以重量份计,将20-40份含氟树脂、5-10份聚合物树脂填料、8-15份光敏性小分子和2-5份无机填料加入到50-70份溶剂中搅拌溶解、反应,得到含光敏基团的氟聚合物涂布液;
(2)将上述含光敏基团的氟聚合物涂布液涂布在表面处理过的基材上,紫外固化,得到紫外交联型的太阳能电池背板;
其中,步骤(2)中所述的涂布方式为浸涂法、刮刀涂布法、狭缝涂布法或气刀涂布法中的任一种。
进一步的,步骤(2)中所述的表面处理是指对基材进行等离子表面处理,处理的线速度为5-100米/分钟,优选的,处理的线速度为10米/分钟。
本发明中的基材经过等离子处理之后表面含有羟基,可以与涂布液中未反应的光敏性小分子反应,使基材两个表面同样修饰上光敏性的分子,从而在紫外光照射下与含氟聚合物耐候层中的光敏基团进行环加成光交联反应,形成化学性质非常稳定的环丁烷交联结构,粘结能力强且稳定,可以有效的解决氟聚合物耐候层从背板中脱落的问题,保证太阳能电池背板在户外恶劣条件下长期使用。
除非明确地说明与此相反,否则,本发明引用的所有范围包括端值。例如,“含氟树脂,20-40份”,表示含氟树脂含量的取值范围为20份≤含氟树脂≤40份。
本发明使用的术语“一个”或“一种”来描述本文所描述的要素和组分。这样做仅仅是为了方便,并且对本发明的范围提供一般性的意义。这种描述应被理解为包括一个或至少一个,并且该单数也包括复数,除非明显地另指他意。
本发明中的数字均为近似值,无论有否使用“大约”或“约”等字眼。数字的数值有可能会出现1%、2%、5%、7%、8%、10%等差异。每当公开一个具有N值的数字时,任何具有N+/-1%,N+/-2%,N+/-3%,N+/-5%,N+/-7%,N+/-8%或N+/-10%值的数字会被明确地公开,其中“+/-”是指加或减,并且N-10%到N+10%之间的范围也被公开。
除非另行定义,否则本文所用的所有科技术语的含义与本发明所属领域的普通技术人员通常理解的一样。尽管与本文所描述的方法和材料类似或等同的方法和材料也可用于本发明实施方案的实施或测试中,但是下文描述了合适的方法和材料。本文提及的所有出版物、专利申请、专利以及其他参考文献均以全文引用方式并入本文,除非引用具体段落。如发生矛盾,以本说明书及其所包括的定义为准。此外,材料、方法和实施例仅是例示性的,并不旨在进行限制。
本发明的有益效果在于:
(1)本发明提供的紫外交联型太阳能电池背板,在紫外光照射下,含有光敏性基团的氟聚合物耐候层与表面处理过的基材PET之间通过[2+2]环加成反应快速形成稳定的环丁烷交联结构,使氟聚合物耐候层与基材PET之间的通过化学键连接,粘结能力强且稳定,可以有效的解决氟聚合物耐候层从背板中脱落的问题,保证太阳能电池背板在户外恶劣环境下长期使用;
(2)本发明提供的紫外交联型太阳能电池背板,不需要添加额外的粘结层,便具有优异的耐候性和粘结性,大大降低了生产成本。
附图说明
图1:本发明提供的太阳能电池背板的结构示意图以及紫外交联机理。
其中:1,PET基材;2,氟聚合物耐候层。
具体实施方式
以下所述的是本发明的优选实施方式,本发明所保护的不限于以下优选实施方式。应当指出,对于本领域的技术人员来说在此发明创造构思的基础上,做出的若干变形和改进,都属于本发明的保护范围,为了进一步描述本发明,下面结合具体实施例来说明。
实施例1
(1)以重量份计,将30份聚偏氟乙烯、10份聚乙烯醇、15份肉桂酰氯、4份二氧化钛粉末加入到50份醋酸乙酯中,机械搅拌,充分溶解、反应1h,得到含光敏基团的氟聚合物涂布液;
(2)将上述含光敏基团的氟聚合物涂布液通过刮刀涂布在PET基材的两面,于紫外线365nm左右光照30min后,热风干燥固化,得到氟聚合物耐候层为30μm的紫外交联型太阳能电池背板;
其中,PET基材的厚度为150μm,在线等离子表面处理的线速度为10米/分钟。
实施例2
(1)以重量份计,将30份聚四氟乙烯、15份聚甲基丙烯酸羟乙酯、15份香豆素-6-磺酰氯、4份二氧化钛粉末加入到50份醋酸丁酯中,机械搅拌,充分溶解、反应1h,得到含光敏基团的氟聚合物涂布液;
(2)将上述含光敏基团的氟聚合物涂布液通过刮刀涂布在PET基材的两面,于紫外线365nm左右光照30min后,热风干燥固化,得到氟聚合物耐候层为25μm的紫外交联型太阳能电池背板;
其中,PET基材的厚度为150μm,在线等离子表面处理的线速度为10米/分钟。
实施例3
(1)以重量份计,将40份聚偏氟乙烯、20份聚甲基丙烯酸羟丙酯、15份的香豆素-6-磺酰氯、4份的二氧化硅粉末加入到50份的甲苯中,机械搅拌,充分溶解、反应2h,制备得到含光敏基团的氟聚合物涂布液;
(2)将上述含光敏基团的氟聚合物涂布液通过刮刀涂布等离子表面处理过的厚度为150μm的PET基材的两面,于紫外线365nm左右光照30min后,热风干燥固化,得到氟聚合物耐候层为25μm的紫外交联型太阳能电池背板;
其中,PET基材的厚度为150μm,在线等离子表面处理的线速度为10米/分钟。
实施例4
(1)以重量份计,将40份乙烯-三氟氯乙烯共聚物、20份聚甲基丙烯酸羟丙酯、15份香豆素-6-磺酰氯、4份二氧化硅粉末加入到50份甲苯中,机械搅拌,充分溶解、反应2h,得到含光敏基团的氟聚合物涂布液;
(2)将上述含光敏基团的氟聚合物涂布液通过刮刀涂布在PET基材的两面,于紫外线365nm左右光照30min后,热风干燥固化,得到氟聚合物耐候层为25μm的紫外交联型太阳能电池背板;
其中,PET基材的厚度为150μm,在线等离子表面处理的线速度为10米/分钟。
实施例5
(1)以重量份计,将40份乙烯-三氟氯乙烯共聚物、20份聚甲基丙烯酸羟丙酯、15份1-(甲基酰氯)胸腺嘧啶、4份二氧化硅粉末加入到50份甲苯中,机械搅拌,充分溶解、反应2h,得到含光敏基团的氟聚合物涂布液;
(2)将上述含光敏基团的氟聚合物涂布液通过刮刀涂布在PET基材的两面,于紫外线265nm左右光照30min后,热风干燥固化,得到氟聚合物耐候层为25μm的紫外交联型太阳能电池背板;
其中,PET基材的厚度为150μm,在线等离子表面处理的线速度为10米/分钟。
对比例
在厚度为150μm的PET基材上两面分别涂布EVA粘合剂,热压贴合厚度为25μm的PVDF薄膜,得到传统背板。
实施例6性能测试
将对比例的传统背板以及实施例1~5所得的紫外交联型太阳能电池背板进行PCT96h老化黄变指数和粘结性测试,测试结果见表1。
表1背板产品的耐候性和粘结性测试结果
由表1的测试结果可知,实施例1-5提供的紫外交联型太阳能电池背板的剥离强度是传统的粘结剂粘合的背板的4倍以上,主要是因为本发明的背板中含光敏基团的氟聚合物耐候层与表面处理过的基材PET之间通过紫外固化形成化学键连接,粘结能力强且稳定,可以有效的解决氟聚合物耐候层从背板中脱落的问题,保证了太阳能电池的使用寿命。
Claims (10)
1.一种紫外交联型太阳能电池背板,其由基材层和涂布于基材两面的氟聚合物耐候层组成,所述氟聚合物耐候层包含以下重量份的组分:含氟树脂,20-40份;聚合物树脂填料,5-10份;光敏性小分子,8-15份;无机填料,2-5份;溶剂,50-70份。
2.如权利要求1所述的紫外交联型太阳能电池背板,其特征在于,所述氟聚合物耐候层的厚度为20-50μm。
3.如权利要求1所述的紫外交联型太阳能电池背板,其特征在于,所述基材为聚对苯二甲酸乙二酯,厚度为100-200μm。
4.如权利要求1所述的紫外交联型太阳能电池背板,其特征在于,所述含氟树脂为聚四氟乙烯、聚偏氟乙烯、乙烯-三氟氯乙烯共聚物、偏氟乙烯-四氟乙烯共聚物中的一种或至少两种的混合物。
5.如权利要求1所述的紫外交联型太阳能电池背板,其特征在于,所述聚合物树脂填料为聚乙烯醇、聚甲基丙烯酸羟乙酯、聚甲基丙烯酸羟丙酯中的一种或至少两种的混合物。
6.如权利要求1所述的紫外交联型太阳能电池背板,其特征在于,所述光敏性小分子为肉桂酰氯、香豆素-6-磺酰氯、1-(甲基酰氯)胸腺嘧啶及其衍生物中的一种或至少两种的混合物。
7.如权利要求1所述的紫外交联型太阳能电池背板,其特征在于,所述无机填料为二氧化钛、二氧化硅、碳酸钙中一种或至少两种的混合物。
8.如权利要求1所述的紫外交联型太阳能电池背板,其特征在于,所述溶剂为醋酸乙酯、丁酮、甲苯、醋酸丁酯中一种或至少两种的混合物。
9.一种制备如权利要求1-8任一项所述的紫外交联型太阳能电池背板的方法,其特征在于,包括:
(1)以重量份计,将20-40份含氟树脂、5-10份聚合物树脂填料、8-15份光敏性小分子和2-5份无机填料加入到50-70份溶剂中搅拌溶解、反应,得到含光敏基团的氟聚合物涂布液;
(2)将上述含光敏基团的氟聚合物涂布液涂布在表面处理过的基材上,紫外固化,得到紫外交联型的太阳能电池背板;
其中,步骤(2)中所述涂布的涂布方式为浸涂法、刮刀涂布法、狭缝涂布法或气刀涂布法中的任一种。
10.如权利要求9所述的紫外交联型太阳能电池背板的制备方法,其特征在于,步骤(2)中所述的表面处理为等离子表面处理,处理的线速度为5-100米/分钟。
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